Method and apparatus for producing olefins

Abstract

The proposed method for producing olefins comprises heating the reaction materials, operating a conversion reactor, converting the materials within the reactor, extracting the product gas, and then cooling the gas. This method utilizes a thermal energy recovery system, which comprises a coaxial inner passage and an outer passage, and a structure that enhances heat transfer between the inner and outer passages. The reaction materials and product gas are passed through the outer and inner passages, respectively, to efficiently transfer heat. Furthermore, the reactor is ignited using a preheated oxidizer gas and fuel gas exceeding 400°C. The thermal system is designed to adhere to specific temperature constraints relating to the sealed portion of the inner passage, ensuring the safety and efficiency of operation. Corresponding matters are also disclosed herein.

Description

Technical Field

[0001] The present disclosure relates to a method and an apparatus for producing olefins.

Background Art

[0002] The steam cracking of hydrocarbon raw materials in a gas combustion steam cracking furnace is an industrial method widely used for producing olefins. In such a method, hydrocarbons such as ethane, propane, butane, condensates, light naphtha, heavy naphtha, gas oil, pyrolysis oil, materials derived from processed refined streams, Fischer-Tropsch products, plastic waste or biomass raw materials are typically preheated to a state of 550 to 650 °C, and then further heated together with steam in a steam cracking furnace, sometimes to a temperature close to 850 °C, to promote the conversion to light olefins such as ethylene and propylene. Since the cracking reaction involved in steam cracking is an endothermic reaction, a significant amount of heat must be supplied. <​​​​​​​​​U.S. Patent No. 1,602,552 relates to a high-pressure heat exchanger or preheater, and more particularly to a heat exchanger used in a petroleum cracking unit to preheat petroleum supplied to a cracking furnace by hot petroleum arriving from the cracking furnace. The proposed configuration provides means to accommodate expansion and contraction. A double-walled pipe is provided, through which the hot petroleum is transported in the inner pipe and constantly surrounded by considerably cooler petroleum at the same pressure until the temperature of the hot petroleum is substantially reduced.

[0006] Russian Patent No. 2663370 relates to a heat exchanger that can be used in power design and transfer. The proposed exchanger includes two concentrically arranged tubes. In the space between the tubes near the outer surface of the inner tube, there is a plate bent in the form of a tube element, the plate having alternating cut openings arranged front to back. The bent elements of the notched surfaces perforated in the form of petals are positioned at an angle to the flow direction of the liquid heat transfer medium.

[0007] In a fluid-fluid heat exchanger disclosed in British Patent Application Publication No. 969036, one fluid outlet is directed toward a pipe carrying the other fluid, the pipe is arranged within one or more annular banks, and a group of radially directed cylindrical outlets is arranged around and within one or more annular banks.

[0008] SAMMoosavi et al., an article published in Int. J. Eng. Res. Technol., Vol. 3, No. 6, June 2014, pp. 820-825, reports on the use of gas turbines to generate power while simultaneously utilizing high-temperature oxygen-enriched exhaust gas. General information on vapor cracking technology can be found in Ullmann's Encyclopedia of Industrial Chemistry, by H. Zimmermann et al., for example, in the entry "Ethylene" in the April 15, 2009 version. [Prior art documents] [Patent Documents]

[0009] [Patent Document 1] International Publication No. 21 / 052642 [Patent Document 2] U.S. Patent No. 1,602,552 [Patent Document 3] Russian Patent No. 2663370 [Patent Document 4] UK Patent Application Publication No. 969036 [Non-patent literature]

[0010] [Non-Patent Document 1] SAMMoosavi et al., an article published in Int. J. Eng. Res. Technol., Volume 3, No. 6, June 2014, pp. 820-825. [Non-Patent Document 2] See, for example, the entry "Ethylene" in the version dated April 15, 2009, in Ullmann's Encyclopedia of Industrial Chemistry, by H. Zimmermann et al. [Overview of the project] [Problems that the invention aims to solve]

[0011] Conventional vapor cracking methods require the combustion of natural gas and / or diesel fuel in a gas combustion vapor cracking furnace, typically with ambient air as the oxidizing gas. The combustion of hydrocarbons in a gas combustion vapor cracking furnace produces carbon dioxide, which is conventionally emitted as part of the flue gas from the furnace. Such emissions are generally undesirable from a current environmental perspective.

[0012] However, olefins are a major building block in chemistry and can often be produced in large quantities, ranging from several hundred thousand tons per year in small steam cracking units to over two million tons per year in single large-scale olefin production facilities. Therefore, olefin production using conventional gas combustion steam cracking furnaces can result in undesirable high emissions of carbon dioxide.

[0013] Because conversion reactions using combustion reactors exist, there is a need for improved methods and apparatus, particularly for endothermic reactions such as vapor decomposition. [Means for solving the problem]

[0014] In view of the above, the Specified herein provides a method and apparatus for producing an olefin having the features of the independent claim. Embodiments are the subject of the dependent claims and the following description.

[0015] The method for producing olefins provided herein includes preheating a gaseous reaction material, igniting a conversion reactor, converting the reaction material in the conversion reactor, drawing a product gas from the conversion reactor, and cooling the product gas drawn from the conversion reactor.

[0016] The reaction raw materials may include one or more hydrocarbons and may further include vapors. Accordingly, in some places below, “hydrocarbon raw materials” is referred to. The product gas may be “raw gas” or “decomposed gas,” as is generally known from the field of vapor decomposition or other transformation reactions. That is, the product gas may be a gas mixture of components whose composition has not changed substantially from the composition directly at the outlet of the transformation reactor. The product gas may or may not undergo processing steps such as compression when processed as proposed herein. Herein, vapor decomposition is described primarily as an exemplary transformation reaction, and the transformation reactor may, in this example, be a vapor decomposition furnace as is generally known in the art. However, the embodiments disclosed herein may also relate to other reactions. Accordingly, where vapor decomposition, or an embodiment of vapor decomposition such as raw materials, product gas, reactor, furnace, radiating or convective zones is referred to herein, this may also refer to a more general transformation reaction, and vice versa.

[0017] The preheating and cooling described herein involve transferring heat from the product gas or a portion of the product gas to the reaction material or a portion of the reaction material using a thermal energy recovery assembly comprising one or more inner passages and one or more outer passages coaxially surrounding the inner passage(s), wherein the outer passages are also referred to herein as “rings,” “annular spaces,” etc. The thermal energy recovery assembly comprises one or more heat transfer enhancing structures that enhance heat transfer from the inner passage(s) to the outer passage(s). These heat transfer enhancing structures are located within the outer passage(s) of the thermal energy recovery assembly. See the following description. The preheating and cooling further include passing the reaction material or a portion of the reaction material through the outer passage(s) of the thermal energy recovery assembly and passing the product gas or a portion of the product gas through the inner passage(s) of the thermal energy recovery assembly.

[0018] The term "passage(s)" is used herein as a concise form of "one or more passages" and "at least one passage". Further, the term "passage" can relate to any kind of space adapted and configured to pass a fluid through a heat energy recovery assembly. In its simplest form, a passage can be provided as a straight tube, but in the embodiments disclosed herein, as further described below, it can be provided as a plurality of tubes including an inner structure or not. Inner passage(s) and outer passage(s) are arranged such that, in particular, a fluid cannot pass through the wall separating the inner passage(s) and the outer passage(s), but may have some porosity or permeability to all specific components of the medium within the heat exchanger.

[0019] Ignition of the reactor involves supplying an oxidant gas at an oxidant gas temperature level above 400 °C using an oxidant gas preheating system and burning a fuel gas containing hydrogen using the oxidant gas at a fuel gas temperature level. The fuel gas can be, for example, pure hydrogen or a hydrogen mixture with ammonia or methane. Alternatively, the fuel gas can contain any hydrocarbon as an addition or alternative to hydrogen. The term "oxidant gas" as used herein shall refer to any gas or gas mixture containing oxygen, such as pure oxygen or essentially pure oxygen, technical grade oxygen, oxygen-enriched air or air. The oxidant gas temperature level can reach values up to 500, 600, 700 or 800 °C in particular, and the oxidant gas is heated to such a temperature at least in part using an oxidant gas preheating system.

[0020] In the method provided herein, the heat energy recovery assembly is configured to meet a set of operating constraint conditions, which are particularly predefined and include a first temperature constraint condition for the outer temperature of the enclosure of the inner passage of the heat energy recovery assembly and a second temperature constraint condition for the inner temperature of the enclosure of the inner passage of the heat energy recovery assembly.

[0021] The "outer temperature" of the enclosure of the inner passage is, in particular, the temperature of the material surface facing the reaction raw material while the reaction raw material passes through the outer passage(s). The "inner temperature" of the enclosure of the inner passage is, in particular, the temperature of the material surface facing the product gas while the product gas passes through the inner passage(s). Thus, the temperature is, in particular, the temperature of one or more walls separating the inner passage(s) from the outer passage(s). The "enclosure" can be, in particular, a formed metal sheet, a tube wall, or any other structural part separating the inner passage(s) and the outer passage(s) from each other.

[0022] The first temperature constraint condition proposed in this specification limits the outer temperature to a first temperature range. The second temperature constraint condition, in particular, limits the inner temperature to a second temperature range. Using the methods and embodiments thereof provided in this specification, heat energy recovery is advantageously implemented, such as operating within a favorable operating regime, and in particular, essentially without performance losses that can occur through premature decomposition of unnecessary and disadvantageous raw materials and / or coking of the effluent. This is possible according to the present disclosure due to the advantageous effect of the heat transfer enhancement structure on the heat transfer rate, despite the heat exchange being carried out between gases, i.e., between the reaction raw material and the product gas.

[0023] Previous solutions have not been able to maintain the corresponding constraint conditions. For example, WO 21 / 052642 teaches compensating for the reduction in the cooling efficiency or capacity (due to low heat transfer coefficient, large heat exchange surface, low cooling rate, and longer residence time) of a gas-gas heat exchanger by increasing the temperature delta. However, this is far from sufficient to achieve the necessary quenching effect and does not address problems such as low cooling rate and critical temperature of the tube wall. These problems can cause premature failure of the device due to the influence of fouling on both sides. Therefore, further measures disclosed in this specification are required. It has also not been recognized by applicants or inventors of the prior art that a raw material-effluent exchanger at the primary quench position can achieve high air preheat temperature and high furnace efficiency respectively.

[0024] As discovered by the inventors of the present invention, according to the embodiments disclosed herein, the heat load for preheating the reaction material in the heat recovery assembly matches the heat load required in the convection zone for oxidizer preheating, which is high but still reasonable from a technical standpoint. Therefore, in particular, the combination of embodiments proposed herein has a synergistic effect that is better than merely an accumulation of advantages.

[0025] In the embodiments disclosed herein, the first temperature range is selected between 550 and 750°C, in particular, depending on the type of reactant. This is advantageous in preventing premature decomposition of the reactant within the outer passage(s) or annular passage(s) of the thermal energy recovery assembly. The upper limit of this first temperature range may be defined in particular by the risk of premature decomposition in the outer passage(s), depending on the type of reactant. In particular, for ethane-type reactants, this upper temperature limit may be 700 to 720°C. In particular, for propane-type reactants, this upper temperature limit may be 680 to 700°C. In particular, for butane-type reactants, this upper temperature limit may be 660 to 680°C. In particular, for naphtha-type reactants, this upper temperature limit may be 640 to 660°C. In particular, for heavier reactants than naphtha, this upper temperature limit may be 540 to 600°C. In the understanding used herein, the raw materials of a particular "species" may contain or consist of at least 50, 60, 70, 80, 90, or 95% by weight, mass, or mol% of the characteristic compound or class of compounds (such as ethane, propane, or butane).

[0026] According to some embodiments, the second temperature range is selected in particular depending on the type of reactant. A lower temperature limit between 150 and 350°C is advantageous in preventing coking of condensates on the gas side as they decompose within the inner passage(s) of the thermal energy recovery assembly. The upper temperature limit of the second temperature range may be determined by the increased risk of coking of chemicals on the inner surface(s) of the inner passage(s) and may be determined by the degree of effluent reactivity at temperatures above 650 to 680°C. The lower temperature limit may be determined by the expected coking reaction by condensates of heavy components of the effluent and may be determined by the type of reactant and decomposition conditions. In particular, for ethane-type reactants, the lower temperature limit may be 180 to 220°C. In particular, for propane-type reactants, the lower temperature limit may be 200 to 250°C. In particular, for butane-type reactants, the lower temperature limit may be 230 to 270°C. For naphtha-type raw materials or raw materials heavier than naphtha (in terms of boiling range), the lower temperature limit may be 280 to 320°C.

[0027] In some embodiments, the thermal energy recovery assembly comprises one heat recovery stage, or several heat recovery stages arranged in parallel or in series, each of which is configured in either a counterflow or parallel flow configuration, wherein in the counterflow configuration, the product gas or a portion of the product gas and the reaction material or a portion of the reaction material pass through the heat recovery stage in opposite directions, and in the parallel flow configuration, the product gas or a portion of the product gas and the reaction material or a portion of the reaction material pass through the heat recovery stage in the same direction. This allows for selective adjustment of the heat transfer characteristics in each stage. In this specification, the term “stage” is used to refer to a separate heat transfer section or unit, which can generally be configured independently of other heat transfer sections or units, and in particular, at least one of the media passing through one of the heat transfer sections can be controlled independently of each other.

[0028] According to one embodiment, the product gas or a portion of the product gas is passed through, for example, one of the heat recovery stages in the parallel flow configuration, in a different heat recovery stage of the heat recovery stage, before being further cooled. This has the particularly advantageous effect of rapidly cooling the product gas in order to essentially immediately stop the decomposition reaction.

[0029] Furthermore, in such embodiments, downstream of the heat recovery stage in the parallel flow configuration, the product gas or a portion of the product gas may be passed through one of the heat recovery stages provided in the counterflow configuration. In other words, different heat recovery stages of the heat recovery stage are located in the counterflow configuration. This embodiment enables particularly effective cooling and utilization of heat at relatively low thermal levels.

[0030] In such embodiments, the product gas may be passed through a thermal energy recovery assembly that generates steam before being cooled in the heat recovery stage provided within the counterflow configuration. That is, the steam-generating thermal energy recovery stage is the first stage of the thermal energy recovery assembly, followed by a second stage of the thermal energy recovery assembly. The second stage may be in a counterflow configuration, a parallel flow configuration, or a combination thereof.

[0031] The steam generation stage may be a separate device from the thermal energy recovery assembly. This allows for the generation of steam in quantities that match the amount required by the method.

[0032] Any embodiment of the thermal energy recovery assembly can be extended downstream by a further, separate steam generating device. That is, as an alternative or addition, a separate thermal energy recovery assembly can be provided to provide a downstream counterflow thermal recovery stage to the thermal energy recovery assembly, particularly as a tube-in-tube heat exchanger and a shell-and-tube heat exchanger, especially in the counterflow configuration described above.

[0033] In some embodiments, downstream of the counterflow heat recovery stage, the product gas may be further cooled within the counterflow stage heat recovery configuration by partially or completely vaporizing the reaction material and the effluent vapor mixture used in at least part of the generation of the reaction material according to certain embodiments. This is particularly advantageous for utilizing heat at lower temperature levels.

[0034] According to some embodiments, the cooling of the product gas or a portion of the product gas is carried out at a rate of at least 2.5 K / ms (Kelvin per millisecond) or at least 4.5 K / ms, in particular at the temperature level of the high-temperature reactor effluent, i.e., at the temperature level of the product gas above 600°C.

[0035] The pressure drop of the product gas or a portion of the product gas passing through the thermal energy recovery assembly can be less than 0.35 bar, less than 0.30 bar, less than 0.25 bar, less than 0.20 bar, or less than 0.15 bar in such a configuration.

[0036] The residence time of the product gas or a portion of the product gas in the thermal energy recovery assembly may be less than 100 ms (milliseconds), less than 95 ms, less than 90 ms, less than 85 ms, less than 83 ms, or less than 80 ms at the high-temperature reactor effluent temperature level above 600°C.

[0037] The pressure drop of the reaction material or a portion of the reaction material passing through the thermal energy recovery assembly can be 2 to 15 bar, 2.5 to 10 bar, 3 to 8 bar, 3 to 10 bar, 4 to 9 bar, or 5 to 8 bar.

[0038] In the method proposed herein, the preheating of the oxidizer in an oxidizer preheating system may include a first indirect heating step of the product mixture to heat, particularly in the temperature range of 180 to 300°C, using an intermediate heat medium, such as high-temperature boiler feedwater heated in a quenching heat exchanger, or high-pressure saturated steam rising in a quenching exchanger, and at least one further oxidizer preheating step, the further oxidizer preheating step particularly includes heating the oxidizer to high-temperature flue gas in the convection zone of the reactor, particularly in the temperature range of 300 to 800°C.

[0039] A thermal energy recovery assembly for use in a method according to any embodiment disclosed herein, namely a method for producing an olefin, is also proposed, the method comprising preheating the reaction materials, igniting a conversion reactor, converting the reaction materials in the conversion reactor, extracting the product gas from the conversion reactor, and cooling the product gas extracted from the conversion reactor.

[0040] Furthermore, this specification proposes an olefin production apparatus particularly suited to the implementation of a vapor decomposition method, including such a thermal energy recovery assembly. The apparatus is particularly suited to preheating the reaction material, igniting the conversion reactor, converting the reaction material within the conversion reactor, extracting the product gas from the conversion reactor, and cooling the product gas extracted from the conversion reactor. The apparatus particularly comprises appropriately configured apparatus sections, devices, etc.

[0041] The following describes thermal energy recovery assemblies and devices, as well as embodiments thereof. The description of the thermal energy recovery assemblies is similar to the description of the devices, and vice versa.

[0042] In particular, the thermal energy recovery assembly is adapted to the implementation of at least a part of the preheating and cooling by transferring heat from the product gas or a portion of the product gas to the reaction material or a portion of the reaction material, and the thermal energy recovery assembly comprises one or more inner passages and one or more outer passages coaxially surrounding the inner passage(s).

[0043] The thermal energy recovery assemblies proposed herein are particularly suited to the implementation of the preheating and cooling, and further include passing the reaction raw materials or a portion of the reaction raw materials through the outer passage(s) of the thermal energy recovery assembly, and passing the product gas or a portion of the product gas through the inner passage(s) of the thermal energy recovery assembly.

[0044] The apparatus is specifically configured to ignite the reactor and includes supplying an oxidizer gas at an oxidizer gas temperature level exceeding 400°C using an oxidizer gas preheating system, and using the oxidizer gas at a fuel gas temperature level to burn a hydrogen-containing fuel gas. According to one embodiment, the oxidizer gas preheating system is also provided.

[0045] The apparatus and / or the thermal energy recovery assembly is configured to satisfy a set of operating constraints, the set of operating constraints including a first temperature constraint relating to the external temperature of the internal passage of the thermal energy recovery assembly, and a second temperature constraint relating to the internal temperature of the internal passage of the thermal energy recovery assembly. In some embodiments, a corresponding control unit suitable for performing the operation can be provided, even if the constraints proposed herein can be reached by a choice in the design of the thermal energy recovery assembly. In both alternative embodiments, the thermal energy recovery assembly is configured to satisfy the set of operating constraints.

[0046] Control strategies managed by the corresponding control unit may include bypasses that control the flow around a single and / or multiple stages of a thermal energy recovery assembly, and / or around bundles within the convection section of a conversion reactor. Such bypasses may be used, for example, to reduce the reaction material inlet temperature to several stages, where required under certain operating conditions. According to some embodiments, bypasses may be provided particularly within the reaction material preheating sequence and / or the oxidizer gas preheating sequence.

[0047] The measurement inputs to the control unit provided according to the embodiments proposed herein may be flow rate and temperature measurements at the inlet / outlet of the heat exchanger or at the stage of the thermal energy recovery assembly, and the flow rate and temperature measurements may be used for model-based calculations of the pipe metal temperature profile using the design information of the actual exchanger.

[0048] As a further measure, in some embodiments, an electric preheater may be provided within the raw material preheating sequence and / or the air preheating sequence. The power supply to the preheater can be adjusted during operation to remain within the temperature constraints of the thermal energy recovery assembly.

[0049] Furthermore, according to the embodiments proposed herein, the final oxidizer gas preheating temperature can also be changed during operation (for example, by using such a bypass), thereby modifying the convection section and, consequently, the temperature profile of the raw material preheating step within the convection section.

[0050] As an alternative to using a control unit, the apparatus provided in the embodiments of this disclosure may be specifically designed to avoid operation in the critical temperature region. The entire quenching process, the thermal energy recovery assembly, and the conversion reactor configuration may be specifically designed to avoid this critical temperature region.

[0051] According to this disclosure, the thermal energy recovery assembly comprises one or more heat transfer enhancing structures that enhance heat transfer from the inner passage to the outer passage, as described above. Embodiments of this disclosure described below in more detail relate to specific configurations of such heat transfer enhancing structures that are particularly located within the outer passage.

[0052] In embodiments proposed herein, the heat transfer reinforcing structure(s) may be provided as at least one of a collision structure, a turbulence-enhancing structure, a high-shear induction structure, and a surface area increasing structure, or may include at least one of these. The outer passage(s) may, in particular, include a first stage that may comprise such a structure. That is, in embodiments, the heat transfer reinforcing structure(s) may be provided as at least one of a collision structure, a turbulence-enhancing structure, a high-shear induction structure, and a surface area increasing structure, and the heat transfer reinforcing structure(s) may be provided in the outer passage(s) of the thermal energy recovery assembly and / or in at least one thermal recovery stage of the thermal energy recovery assembly.

[0053] In one embodiment provided herein, the outer passage of a thermal energy recovery assembly comprises a plate impact configuration between an upstream end and a downstream end, the plate impact configuration comprising a first passage having a stepped inlet at the upstream end and closed to the flow at the downstream end, a second passage having a stepped outlet at the downstream end and disposed between the first passage and the inner passage, and a wall separating the first passage from the second passage, the wall defining an opening that fluidly connects the first passage and the second passage, the plate impact configuration is configured to receive the reaction material through the stepped inlet, pass the reaction material from the first passage through the opening in the wall to the second passage, cause the reaction material flow to collide with the outer surface of the inner passage, and discharge the reaction material through the stepped outlet of the second passage. The opening in the wall may be provided in particular by regular or irregular punched holes in the wall.

[0054] In some embodiments provided herein, the thermal energy recovery assembly further comprises an outer passage comprising a piccolo impact section, the piccolo impact section comprising an upstream divider disposed within the outer passage around an inner passage, a downstream divider disposed within the outer passage around an inner passage downstream of the upstream divider in the outer passage and defining at least one stage outlet, a chamber defined within the outer passage around an inner passage between the upstream and downstream dividers, and a piccolo passage offset from the inner passage, the piccolo passage extending through the chamber from the upstream divider to the downstream divider, the piccolo passage including a stage inlet for receiving incoming raw material, the piccolo passage including a plurality of openings defined therein, the piccolo impact section configured to receive raw material from the stage inlet, flow the raw material from the piccolo passage through the plurality of openings into the chamber, and discharge the raw material from the chamber through at least one stage outlet.

[0055] The terms "plate impact section" and "piccolo impact section" are used herein as is customary in this art.

[0056] In the thermal energy recovery assembly, the outer passage may comprise at least one first stage and a second stage, the first and second stages being in series, and both stages comprising at least one heat transfer reinforcing structure.

[0057] In the embodiment, the passage of the thermal energy recovery assembly is equipped with a heat transfer enhancement structure, the heat transfer enhancement structure comprises at least one of a turbulence promotion structure, a high shear induction shape, and a surface area increasing section.

[0058] According to some embodiments, the thermal energy recovery assembly may comprise a plurality of parallel inner passages, each inner passage may be located within an outer passage, and each outer passage may comprise at least one of a collision structure, a turbulence-enhancing structure, a high-shear induction shape, and a surface area increasing section that enhances heat transfer from the inner passage to the outer passage.

[0059] The exemplary embodiments summarized above and other embodiments, as well as other aspects and advantages, are described in detail herein. Furthermore, it should be understood that the above information and the following detailed description provide merely illustrative examples of various aspects and embodiments and are intended to provide an overview or framework for understanding the nature and features of the claimed aspects and embodiments. Accordingly, these and other objectives, along with the advantages and features of this disclosure, will become clear with reference to the following description and accompanying drawings. Furthermore, it should be understood that the features of the various embodiments described herein are not mutually exclusive and various combinations and substitutions may exist.

[0060] The accompanying drawings, included to provide a further understanding of embodiments of this disclosure, are incorporated herein and constitute part of this specification, serving to illustrate embodiments of this disclosure and to illustrate the principles of embodiments described herein together with the detailed description. It is not intended to provide a basic understanding of embodiments described herein or to show structural details of this disclosure in more detail than is required for various ways in which embodiments can be carried out. By convention, various features in the drawings described below are not necessarily drawn to a constant scale. Dimensions of various features and elements in the drawings may be enlarged or reduced to more clearly show embodiments of this disclosure. [Brief explanation of the drawing]

[0061] [Figure 1A] This is a schematic diagram of a high-efficiency, low-emission combustion furnace assembly, which is combined with a thermal energy recovery assembly for high-temperature reactor effluent according to an embodiment of the present disclosure. [Figure 1B] This is a schematic diagram of a high-efficiency, low-emission combustion furnace assembly, which is combined with a thermal energy recovery assembly for high-temperature reactor effluent according to an embodiment of the present disclosure. [Figure 1C] This is a schematic diagram of a high-efficiency, low-emission combustion furnace assembly, which is combined with a thermal energy recovery assembly for high-temperature reactor effluent according to an embodiment of the present disclosure. [Figure 1D]This is a schematic diagram of a high-efficiency, low-emission combustion furnace assembly, which is combined with a thermal energy recovery assembly for high-temperature reactor effluent according to an embodiment of the present disclosure. [Figure 1E] This is a schematic diagram of a high-efficiency, low-emission combustion furnace assembly, which is combined with a thermal energy recovery assembly for high-temperature reactor effluent according to an embodiment of the present disclosure. [Figure 1F] This is a schematic diagram of a high-efficiency, low-emission combustion furnace assembly, which is combined with a thermal energy recovery assembly for high-temperature reactor effluent according to an embodiment of the present disclosure. [Figure 2A] This is a partial schematic cross-sectional side view of an exemplary thermal energy recovery assembly according to an embodiment of the present disclosure. [Figure 2B] This is a partial schematic cross-sectional end view taken along line BB of the exemplary assembly shown in Figure 2A according to an embodiment of the present disclosure. [Figure 3A] This is a partial schematic perspective view of another exemplary thermal energy recovery assembly according to an embodiment of the present disclosure. [Figure 3B] This is a partial schematic cross-sectional end view taken along line BB of the exemplary assembly shown in Figure 3A according to an embodiment of the present disclosure. [Figure 4A] This is a schematic cross-sectional view of an exemplary inner passage having exemplary round protrusions on its inner surface, according to an embodiment of the present disclosure. [Figure 4B] This is a schematic cross-sectional view of an exemplary inner passage having a rectangular projection on its inner surface, according to an embodiment of the present disclosure. [Figure 5] This is a block diagram of an exemplary olefin manufacturing method according to an embodiment of the present disclosure. [Figure 6] This is a schematic diagram of possible flow paths on the high-temperature reactor effluent side and the raw material side in a single-stage or two-stage thermal energy recovery assembly according to embodiments of the present disclosure. [Figure 7] This is a schematic diagram of possible flow paths on the high-temperature reactor effluent side and the raw material side in a single-stage or two-stage thermal energy recovery assembly according to embodiments of the present disclosure. [Figure 8]This is a schematic diagram of possible flow paths on the high-temperature reactor effluent side and the raw material side in a single-stage or two-stage thermal energy recovery assembly according to embodiments of the present disclosure. [Figure 9] This is a schematic diagram of possible flow paths on the high-temperature reactor effluent side and the raw material side in a single-stage or two-stage thermal energy recovery assembly according to embodiments of the present disclosure. [Figure 10] This is a schematic diagram of possible flow paths on the high-temperature reactor effluent side and the raw material side in a single-stage or two-stage thermal energy recovery assembly according to embodiments of the present disclosure. [Modes for carrying out the invention]

[0062] The drawings include similar figures to show similar parts throughout several drawings, and the following description is given as possible teachings of exemplary embodiments, and those skilled in the art will understand that numerous modifications can be made to the embodiments described. It will also be apparent that some of the desired benefits of the embodiments described can be obtained by selecting some of the features of the embodiments without utilizing other features. Thus, those skilled in the art will understand that numerous modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Accordingly, the following description is given to illustrate the principles of the embodiments and not as a limitation on the principles of the embodiments.

[0063] The expressions and terminology used herein are for illustrative purposes only and should not be considered limiting. The term “plural” as used herein refers to two or more items or components. The terms “equip,” “include,” “hold,” “possess,” “contain,” and “accompany” are open-ended terms, whether they appear in the specification or in the claims, etc., meaning “not limiting, but including,” unless otherwise stated. Therefore, the use of such terms means to include the items listed below and their equivalents, as well as any further items. The transitional phrases “consist of” and “essentially consist of” are closed or semi-closed transitional phrases to any claim, respectively. The use of ordinal terms such as "first," "second," and "third" modifying elements of a claim in the claims does not in itself imply any priority, order, or sequence of one element of a claim over the other, or the chronological order in which the actions of the method are performed, but is merely used as a distinguishing mark to differentiate one element of a claim having a specific name from another element of the same name (except for the use of ordinal terms).

[0064] Furthermore, while this specification may refer to quantitative measures, values, shape relationships, etc., unless otherwise stated, any one or more of these may be absolute or approximate, taking into account possible acceptable variations, such as those due to manufacturing or engineering tolerances.

[0065] Figures 1A to 1F schematically illustrate the concept, i.e., apparatus, of a high-efficiency, low-emission combustion furnace assembly, combined with a thermal energy recovery assembly and oxidizer preheating, according to embodiments of the present disclosure. In some embodiments, the gas combustion furnace assembly may be used to produce olefins from reaction materials such as ethane, propane, butane, condensates, light naphtha, heavy naphtha, diesel fuel, pyrolysis oil, materials derived from processing and refining flows, Fischer-Tropsch products, plastic waste, and / or biological raw materials.

[0066] Before referring to the features and advantages of the apparatus provided herein, some features of the conventional apparatus will be mentioned based on Figures 1A to 1F, and the advantageous solutions provided herein will be explained.

[0067] In conventional gas-combustion olefin production furnaces or conversion reactors, combustion may only supply heat to the decomposition reaction when the temperature exceeds the reaction temperature, for example, from 550 or 650°C to 850°C. In the understanding used herein, a gas-combustion olefin production furnace is selected as one of the conversion reactors that can be used by this disclosure, and the more general terms “reaction material,” “conversion reactor,” and “product gas” are used for decomposition material, decomposition furnace, and decomposition gas or raw gas.

[0068] Heating above the reaction temperature is carried out in the so-called radiant area or section indicated by reference numeral 10 in Figures 1A to 1F. After the fuel gas or flue gas has cooled below this temperature in radiant area 10, there may be a desire to extract as much remaining heat as possible to achieve energy-efficient operation. This heat is recovered in the so-called convection area or section extending downstream from the location of reference numeral 9 in Figures 1A to 1F. Radiant area 10 and convection area 9 are often commonly referred to as the “furnace.” The remaining energy is used to preheat the reactor raw materials and diluent vapors in convection area 9 to the temperature required for the decomposition reaction to begin, as will be further described in detail below.

[0069] In olefin production, after the decomposition of the raw materials, the reactor effluent should be cooled before further processing of the decomposed gases. Ideally, the initial cooling should be carried out quickly to reduce or prevent side reactions in the reactor effluent while it is still relatively hot. Furthermore, for energy-efficient processing, the heat from the reactor effluent should be recovered to the maximum extent possible, technically or economically feasible, for use elsewhere in the process.

[0070] In some systems, this rapid cooling and quenching takes place within a so-called transfer line exchanger (TLE), where the reactor effluent is cooled by exchanging heat with liquid water to generate high-pressure steam. Cooling by heat exchange with boiling water has the advantage that heat transfer is generally faster than when cooling with gas, sometimes five or even ten times faster in the same exchanger configuration. This steam can be used to power a steam turbine or other auxiliary equipment.

[0071] For example, steam is typically used to power compressors for decomposed gases, one or more refrigeration compressors, or one or more pumps. While the use of steam to drive rotating equipment such as compressors and pumps is a convenient way to utilize the energy recovered from cooling reactor effluents, the efficiency of converting energy into mechanical work in the form of heat (e.g., heat contained in the steam) is typically low, ranging from 30 to 50%.

[0072] A solution to reduce the large amount of carbon dioxide produced by conventional vapor decomposition processes is to reduce the load on the furnace ignition by returning as much of the remaining combustion heat that cannot be used in the decomposition reaction back to the radiating area for reuse as much as possible. This can be achieved by preheating the oxidizer to the high-temperature flue gas outside and / or inside the convection area. Combustion vapor decomposition furnaces with high levels of oxidizer preheating have lower emissions compared to conventional gas combustion decomposition furnaces without oxidizer preheating. Decomposition furnace emissions can be further reduced by combining oxidizer preheating with the combustion of pure hydrogen or a hydrogen-containing fuel gas mixture. Further reductions in decomposition furnace emissions are possible by further fuel gas preheating.

[0073] However, these low-emission, high-efficiency steam cracking furnaces present new technical challenges that must be overcome. One consequence of using high-temperature flue gas for oxidizer preheating in the combustion cracking furnace is the lack of heat to heat the raw materials and diluent steam, which must be supplied by other means. A second consequence is the need to incorporate different energy sources into the cracking process. Electricity is used to power multiple pumps, such as compressors and pumps. Rotating equipment such as compressors and pumps can easily be powered by electricity. Furthermore, the operating efficiency of such equipment powered by electricity is considerably higher than that powered by steam, with energy efficiencies generally exceeding 90% achieved when using electricity, compared to the 30 to 50% typically obtained when using steam. Therefore, there is considerable incentive to power these devices with electricity in a highly efficient steam cracking process. This means that the energy currently recovered when cooling the reactor effluent can no longer be used to power pumps and compressors. Rather, it is necessary to find different uses for this energy so that the overall energy efficiency of the steam cracking process can be maintained at a high level. Such uses are provided, in particular, by embodiments disclosed herein.

[0074] In the context of this disclosure, for a highly efficient, low-emission steam cracking process, the need for a system and method for convection zone design has been identified, which incorporates preheating of the oxidizer gas in addition to other heating services. Furthermore, the need for a system and method that utilizes energy obtained from the quenching of high-temperature reactor effluent while still quenching the cracked gas sufficiently rapidly to prevent further reactions, and that is as reliable as conventional steam rise quenching systems, has been identified, as well as a preferred operating window / regime that prevents undesirable performance loss through premature cracking of the raw materials and / or coking of the effluent in thermal energy recovery assemblies. Furthermore, the need for a system and method for preheating the raw materials by reducing the available fuel gas heat in a low-emission combustion furnace has been identified.

[0075] The needs and solutions to these problems have already been summarized above and will be explained in more detail below.

[0076] In other words, as stated above, the proposed method includes preheating the reaction material, i.e., reaction material with or without vapor, within a thermal energy recovery assembly to produce preheated reaction material, and supplying the preheated reaction material to a high-efficiency, low-emission combustion conversion reactor. The conversion reactor may, in particular, be a decomposition reactor equipped with a reaction or radiation area 9, which heats and converts the preheated material, particularly by vapor decomposition, and outputs a high-temperature reactor effluent containing decomposed hydrocarbons, i.e., olefins and unconverted hydrocarbons. The reactor effluent is also referred to herein as “product gas,” as already stated. The preheated oxidizer or oxidizer gas is burned to heat the conversion reactor or its reaction area. The high-temperature reactor effluent or product gas is cooled within the thermal energy recovery assembly by transferring heat to the reaction material. The proposed method advantageously includes configuring thermal energy recovery to operate within a preferred operating regime without performance loss through premature decomposition of the material and / or coking of the effluent, as already stated above.

[0077] As described above, in the thermal energy recovery assembly, one or more stages may be provided in a series or parallel configuration, with each of these stages having a counterflow or parallel flow direction. Combinations of parallel and counterflow configurations may also be provided. The detailed layout of these stages may differ in part or completely in terms of layout, inner and outer passages, and heat transfer enhancement methods and structural components.

[0078] In some embodiments of the thermal energy recovery assembly, individual stages are sized to ensure that thermal energy recovery operates within the operating regime without performance loss. Performance loss may occur when a fouling layer is formed on the inner or outer surface of the inner passage (i.e., the surface of the inner passage's containment as described above) through chemical and / or physical processes, reducing heat transfer from the inner passage to the outer passage. In addition to the reactant species and composition and the composition of the product gas, these chemical and physical processes are highly dependent on the temperature prevailing on the inner and outer surfaces of the inner passage or its containment.

[0079] Such processes are the premature decomposition of raw materials in the outer passage and chemically and physically induced coking in the inner passage. The premature decomposition of raw materials in the outer passage specifies a certain upper temperature level that cannot be exceeded on the outer surface of the inner passage. A further upper temperature level that cannot be exceeded on the inner surface of the inner passage is specified by the acceleration of chemical coking at high surface temperatures. A lower temperature level that cannot be exceeded on the inner surface of the inner passage is specified by coking, which is reached by the condensation of heavy components in the effluent. The specific temperature ranges have already been shown above.

[0080] In one embodiment 100 shown in Figure 1A, a liquid raw material 21, for example, naphtha, is preheated and partially vaporized in a primary raw material preheater convection bank 1. The convection bank, as understood herein, is a configuration of one or more heat recovery structures or bundles in the convection area 9 of the corresponding furnace or reactor. The partially vaporized naphtha 22 is then mixed with superheated dilution steam using a mixing nozzle 20. The dilution steam is brought from steam 30 superheated against very high-pressure saturated steam (the term "very high-pressure steam" or VHP steam refers to steam at a pressure level of 100 to 130 bar) in a separate heat exchanger unit, namely a primary dilution steam superheater 44, and may then be further superheated against flue gas in the convection area 9 within a secondary dilution steam superheater 4. The mixture of raw material and dilution steam is then further superheated in a secondary raw material preheater convection bank 3. Next, as shown in 23, the mixture is supplied to the countercurrent stage 13 of the thermal energy recovery assembly 110, where it is heated against the pre-quenched high-temperature reactor effluent or product gas that has already passed through the portion 12 of the thermal energy recovery assembly 110.

[0081] The reaction material 24 leaves stage 13 of the thermal energy recovery assembly 110 at the high-temperature end and is sent to the high-temperature end of countercurrent stage 12, where the reaction material 24 is further heated by the high-temperature reactor effluent or product gas 27 arriving from the decomposition coil 11 in the radiating section 10. Other configurations of the thermal energy recovery assembly 110, such as those shown in Figures 6 to 10, are also possible for this embodiment 100 and further embodiments shown below in Figures 1B to 1F. After being heated in both stages 12 and 13 of the thermal energy recovery assembly 110, the material 25 is transferred to the high-temperature coil 8 in the convection section 9 of the combustion furnace, where, in the convection section 9 shown now 26, the material 25 is heated to near its decomposition temperature and then transferred to the decomposition coil 11. The reaction material is then decomposed in the coil 11, yielding a high-temperature reactor effluent or product gas 27 containing the desired product.

[0082] The heat for the decomposition reaction is supplied by burning pure hydrogen or hydrogen-containing fuel gas 41 together with a preheated oxidizer or oxidizer gas 36 in the radiating area 10. To supply the preheated oxidizer gas 36, an unheated oxidizer gas 32 is supplied, and preheating is achieved in two steps: an oxidizer blower 18 supplies the oxidizer to an external primary oxidizer preheater 17, where the oxidizer gas 32 is heated by a steam drum 15 against high-pressure saturated steam. The oxidizer gas, now indicated as 35, is then sent to a secondary oxidizer preheater convection bank 7 in the convection area 9 of the combustion decomposition furnace and supplied to the combustor in the radiating area 10 for combustion. In some embodiments, the secondary oxidizer preheater 7 may comprise multiple bundles arranged vertically in series up and down within the convection area, as is generally known in the art.

[0083] Steam from the steam drum 15 rises within the secondary quenching exchanger device 14, which further cools the pre-quenched high-temperature reactor effluent or product gas 28 arriving from the thermal energy recovery assemblies 12 and 13. Saturated steam 38 from the steam drum 15 is used for heating purposes (heaters 17, 42, 43, 44), and a portion of the saturated steam from the steam drum 15 is sent to steam superheated convection banks 5 and 6. Boiler feedwater 31 is injected through nozzles between steam superheated convection banks 5 and 6 to regulate the temperature of the superheated steam 40. Superheaters 42 and 43, shown in shaded form, can be considered as alternatives to heat exchangers 44 or further heaters for heavy feedstocks with high boiling points, such as heavy naphtha or atmospheric pressure diesel.

[0084] The high-temperature condensate 33 from heaters 17, 42, 43, and 44 is returned to the steam drum 15, thus reducing the amount of boiler feedwater 37 needed for replenishment. The high combustion temperature in the radiating area 10 due to oxidizer preheating and / or hydrogen combustion can cause an increase in nitrogen oxide (NOx) content in the flue gas. Therefore, a selective catalytic reduction unit, hereafter referred to as a DeNOx unit, may be advantageous in reducing NOx emissions into the atmosphere. The DeNOx unit 2 requires a specific flue gas temperature window for effective NOx removal and, therefore, in this embodiment, is installed in the convection section 9 between heat recovery banks 1 and 3, and a portion of the flue gas can be reused upstream of the DeNOx unit 2.

[0085] Further elements shown in Figure 1A include a flue gas blower 19, through which the flue gas blower 19 draws the flue gas, indicated by 34, from the convection area 9. The product gas 27 downstream of the thermal energy recovery assemblies 12 and 13 is indicated by 28, and the product gas 28 downstream of the heat exchanger 14 is indicated by 29.

[0086] In some embodiments, as shown in Figure 1B for one embodiment 200, the convection section of the combustion furnace may not require a high-temperature coil 8 within the convection section 9. In this embodiment, the heated raw material 25 from the thermal energy recovery assembly 110 is sent directly to the decomposition coil 11 to decompose the hydrocarbons contained in the raw material 25. This allows for oxidizer preheating to an even higher temperature level in the secondary oxidizer preheater 7.

[0087] In one embodiment 300 shown in Figure 1C, more heat is transferred from the high-temperature reactor effluent to the raw material flow than in embodiment 100 in Figure 1A. This allows for a higher level of oxidizer preheating in the separate primary high-temperature oxidizer preheater convection bank 6 and secondary high-temperature oxidizer preheater convection bank 8, with the high-temperature coil 7 located between them.

[0088] In one embodiment 400 shown in Figure 1D, the gaseous raw material 21, for example ethane, is preheated in the primary raw material preheater convection bank 1. Next, the gaseous raw material 21 is mixed with dilution vapor 30 in the mixing nozzle 20. The mixture 23 of raw material and dilution vapor is then supplied to the counterflow stage 13 of the thermal energy recovery assembly 110, where the mixture is heated against the pre-quenched high-temperature reactor effluent or product gas 27 that has already passed through section 12 of the thermal energy recovery assembly 110. The raw material 23, now shown 24, leaves the stage 13 of the thermal energy recovery assembly 110 at the high-temperature end and is sent to the high-temperature end of the counterflow stage 12 of the thermal energy recovery assembly 110, where the raw material 23, now shown 24, is further heated against the high-temperature reactor effluent or product gas 27 arriving from the decomposition coil 11. After being heated at both stages of the thermal energy recovery assembly 110, the raw material indicated at 25 is transferred to the high-temperature coil 7 in the convection section of the combustion furnace, where it is then heated to near its decomposition temperature, and then the raw material indicated at 26 is transferred to the decomposition coil 11.

[0089] Next, the reaction material is decomposed in the coil, yielding a high-temperature reactor effluent or product gas 27 containing the desired product. Heat for the decomposition reaction is supplied by burning hydrogen or hydrogen-containing fuel gas 36 together with preheated oxidizer or oxidizer gas 41 in the radiating area 10. To supply the preheated oxidizer gas 41, an unheated oxidizer gas 32 is supplied, and preheating is achieved in two steps: an oxidizer blower 18 supplies the oxidizer to an external primary oxidizer preheater 17, where the oxidizer is heated against the high-temperature boiler feedwater 37. Next, the oxidizer, now indicated 35, is sent to a secondary oxidizer preheater convection bank 6 in the convection area 9, then, in a third step, is heated in a tertiary oxidizer preheater convection bank 8 of the combustion decomposition furnace, and finally supplied to the combustor in the radiating area 10 for combustion. In some embodiments, the secondary oxidizer preheater 6 and the tertiary oxidizer preheater 8 may comprise multiple bundles arranged vertically in series within the convection zone 9.

[0090] Steam from the steam drum 15, which may be high-pressure steam of 60 to 80 bar or ultra-high-pressure steam of 100 to 130 bar, rises in the secondary quenching exchanger device 14, which further cools the pre-quenched high-temperature reactor effluent or product gas 28 arriving from the thermal energy recovery assembly 110. Saturated steam 38 from the steam drum 15 is sent to steam superheated convection banks 4 and 5, and boiler feedwater 31 is injected through temperature control nozzles (not specifically shown) between steam superheated convection banks 4 and 5. In this embodiment, the boiler feedwater acts as a heat transfer medium for transferring heat from the decomposed gas to the oxidizer preheater. The boiler feedwater 37 is heated in the tertiary quenching cooler 14a relative to the pre-quenched and decomposed gas 28, and then cooled in the primary oxidizer preheater 17 in a second step. Next, the cooled boiler feedwater is supplied to the economizer convection bank 2 in the convection section 9 before being sent to the steam drum 15.

[0091] High combustion temperatures within the radiating area 10 due to high levels of oxidizer preheating and / or hydrogen combustion can lead to an increase in NOx content in the flue gas. Therefore, a DeNOx unit may be needed to reduce NOx emissions into the atmosphere. The DeNOx unit 3 requires a specific flue gas temperature window for effective NOx removal and is therefore installed in this embodiment within the convection section 9 between heat recovery banks 2 and 4.

[0092] In some embodiments 500 for gaseous feedstock shown in Figure 1E, heated boiler feedwater 37 may be used not only to preheat the oxidizer for combustion but also to preheat the fuel 36 in a parallel fuel preheater 50 using a lateral flow 51.

[0093] In particular, in some embodiments 600 shown in Figure 1F for heavy reaction fuels such as atmospheric pressure diesel fuel, the preheated fuel 22 from the primary fuel preheater 1 is mixed with process vapor 30 in a first mixing nozzle 20a and can then be sent to the parallel flow stage 13 of the thermal energy recovery assembly 110, where the fuel 22 is partially or completely vaporized against the high-temperature reactor effluent 27 that has already passed through a portion 12 of the thermal energy recovery assembly and been pre-quenched. Next, the fuel flow 24 is sent to a second mixing nozzle 20b, where the fuel flow 24 is mixed with superheated dilution vapor 30 arriving from the dilution vapor superheater convection bank 3. Any residual liquid phase in 24 is vaporized by instantaneous vaporization in 20b and sent in gaseous state to the parallel flow stage 13 of the thermal energy recovery assembly, where the fuel flow 24 is further superheated against the high-temperature reactor effluent. The raw material 26 can be supplied directly to the decomposition coil 11 or further preheated in the high-temperature coil 7 to generate the raw material flow 27. The oxidizer preheating and steam superheating can be essentially similar to that of embodiment 100 shown in Figure 1A.

[0094] As used herein, “product gas” and “high-temperature reactor effluent” are synonymous with reactor effluent located downstream of the decomposition coil 11 of the combustion furnace 100 in Figures 1A to 1F, and which has cooled from the temperature at which it left the furnace. In some embodiments, the thermal energy recovery assemblies 12 and 13 may include one or more stages, for example, a first stage 12 and a second stage 13 shown in Figures 1A to 1F. In some embodiments including two or more stages, the stages may have substantially the same structural configuration, and in some embodiments including two or more stages, one or more stages may have a structural configuration different from the structural configuration of the other stages. In some embodiments including two or more stages, two or more stages may be in series with respect to each other (e.g., physically and / or with respect to processing) (see, for example, Figures 1A to 1F), and in some embodiments including two or more stages, two or more stages may be in parallel with respect to each other (e.g., physically and / or with respect to processing).

[0095] In some embodiments, the combustion furnace may be configured to receive raw materials, heat them to a reaction temperature, and produce a high-temperature reactor effluent. In some embodiments, the raw materials and / or effluent may be in the form of liquids, gases, or combinations thereof. For example, the reactors in Figures 1A to 1F are high-efficiency, low-emission combustion cracking furnaces, where the raw materials may be or contain hydrocarbons for cracking in the furnace, and may produce a high-temperature reactor effluent containing hydrocarbons that have been cracked, for example, at least partially in a gaseous state (e.g., completely in a gaseous state). In some embodiments, the furnace may be configured to heat the raw materials to a cracking temperature, crack the hydrocarbons into a desired product, the desired product may be discharged from the furnace as a high-temperature reactor effluent. The raw materials may include, for example, ethane, propane, butane, condensates, light naphtha, heavy naphtha, diesel fuel, pyrolysis oil, materials derived from processing and refining flows, Fischer-Tropsch products, plastic waste, and / or biological raw materials. The raw materials may further include steam. In some embodiments, the combustion furnace may be configured to receive raw materials into one or more reactor sections or reactor chambers (e.g., a passage in a decomposition unit or the decomposition coil 11 in Figure 1A) via the reactor raw material pipeline 26 shown in Figures 1A to 1F, and to discharge high-temperature reactor effluent via the reactor effluent pipeline 27 shown in Figures 1A to 1F. In some embodiments, the furnace may heat the raw materials to decomposition temperature by combustion of fuel gases such that the coil 11 flows substantially continuously into the reactor chamber(s) through the reactor raw material pipeline 26, and discharge them from the reactor chamber(s) as high-temperature reactor effluent via the reactor effluent pipeline 27. The reactor chamber(s) may be heated by radiative and convective heat transfer of the fuel. To increase efficiency, the raw materials may be preheated to a temperature close to the decomposition temperature of the raw materials before entering the coil 11 (e.g., upstream of the coil 11).

[0096] In some embodiments, the thermal energy recovery assembly 110 shown in Figures 1A to 1F may be or include a gas-to-gas energy recovery device or heat exchanger. The thermal energy recovery assembly 110 may be configured to receive high-temperature reactor effluent or product gas 27 from a reactor chamber(s) or coil 11, rapidly cool the high-temperature reactor effluent or product gas 27 to a rapid cooling temperature, preserve the desired product in the reactor effluent, and / or prevent side reactions from occurring in the reactor effluent or product gas 27 as it cools. In some embodiments, a single thermal energy recovery assembly 110 may receive high-temperature reactor effluent from a plurality of reactor chambers or coils within a plurality of reactor chambers. In certain embodiments, a single reactor chamber or coil 11 within a single reactor chamber may supply high-temperature reactor effluent to a plurality of thermal energy recovery assemblies 110. The ratio between the number of coils 11 in the reactor chamber or within the reactor chamber and the number of thermal energy recovery assemblies 110 may, in an embodiment, be in the range of 0.1 to 10, for example, in the range of 0.5 to 2.

[0097] The high-temperature reactor effluent or product gas 27 enters the thermal energy recovery assembly 110 at a temperature of at least 550°C, at least 575°C, at least 600°C, at least 610°C, at least 620°C, at least 625°C, at least 630°C, at least 640°C, at least 650°C, at least 700°C, at least 750°C, at least 800°C, or at least 850°C. To rapidly cool the high-temperature reactor effluent or product gas 27, the thermal energy recovery assembly 110 may utilize the raw materials as a cooling medium, for example, before the raw materials enter the coil 11 (for example, upstream of the coil 11). Cooling the high-temperature reactor effluent or product gas 27 within the thermal energy recovery assembly 110 may preheat the raw materials to a temperature close to their decomposition temperature (for example, to a temperature of at least 350°C, at least 375°C, at least 400°C, at least 450°C, at least 500°C, or at least 550°C). As used herein, “rapidly cooled reactor effluent” or “rapidly cooled product gas” refers to reactor effluent or product gas that has passed through the thermal energy recovery assembly 110. In some embodiments, the high-temperature reactor effluent may be further partially cooled or rapid cooled before or after passing through the thermal energy recovery assembly 110. In some embodiments, the preheated raw materials may be further heated (for example, by the high-temperature coil in the convection area 9) before entering the reactor chamber.

[0098] In some embodiments, as shown by 1000 through Figures 2A to 3B, but which can be used similarly in all embodiments through Figures 1A to 1F, a thermal energy recovery assembly can be configured to recover thermal energy from high-temperature reactor effluent and heat the feedstock to a high-efficiency, low-emission combustion cracking furnace.

[0099] As described herein with reference to Figures 2A to 3B, in some embodiments the thermal energy recovery assembly 1000 may include an inner tube or passage 1034 and an outer tube or passage 1040. The inner passage 1034 may include a first inlet configured to receive high-temperature reactor effluent from a low-emission gas combustion cracking furnace. The outer passage 1040 may be arranged around the inner passage 1034 so as to surround an outer ring 1044 around the inner passage 1034. The terms “outer passage” and “ring” (and derivatives thereof) are used herein partially or completely synonymously, but the “outer ring 1044” may or may not be defined by an inner and outer circle that results in an annular cross-section having an inner and outer circular boundary. In some embodiments, the inner and / or outer boundaries of the cross-section may have a shape other than circular, such as a triangle, rectangle, polygon, ellipse, or oval. In some embodiments, the central axis of the inner passage may coincide with the central axis of the outer passage. In some embodiments, the central axis of the inner passage may be offset from the central axis of the outer passage. Thus, the term “ring” (and its derivatives) may be interpreted similarly. The outer passage 1044 may include a second inlet configured to receive feedstock into a high-efficiency, low-emission combustion cracking furnace. The outer passage 1044 may be configured to use the feedstock for the combustion cracking furnace as a cooling medium and to recover thermal energy from the high-temperature reactor effluent before supplying the feedstock to the combustion cracking furnace.

[0100] The outer passage 1044 may be configured to enhance heat transfer from the high-temperature reactor effluent to the raw materials. In some embodiments, the high-temperature reactor effluent may reach a first inlet via an effluent gas inlet chamber or other connector. In some embodiments, cooling may be supplied to a raw material gas inlet chamber or other connector. In some embodiments, the effluent gas inlet chamber may connect one or more reaction chambers to one or more inner passages. In some embodiments, a header may be provided to connect raw materials to two or more outer passages 1044. In some embodiments, cooled and decomposed gases from two or more inner passages 1034 may be collected using a header. In some embodiments, heated raw materials from two or more outer passages 1044 may be combined via a header. In some embodiments, multiple rings 1044 may be included within a single mechanical device capable of receiving high-temperature effluent from multiple decomposition coils via gas inlet chambers or other connectors and receiving low-temperature raw materials from a raw material header.

[0101] In some applications, the residence time and / or pressure drop of the reactor effluent in the thermal energy recovery assembly 110 (Figures 1A to 1F) or the thermal energy recovery assembly 1000 (Figures 2A to 3B) may affect the process and / or product achieved by the heating process. The residence time and pressure drop that occur as the high-temperature reactor effluent passes through the thermal energy recovery assembly 110 or 1000 may affect the ethylene selectivity of the product produced by the furnace assembly. Residence time may be defined as the time above the decomposition temperature of the high-temperature reactor effluent, e.g., 550 or 650°C. In some embodiments, both residence time and pressure drop may be balanced during the quenching of the high-temperature reactor effluent, for example, to preserve the ethylene selectivity of the reactor effluent. For example, an increase in the pressure drop within the thermal energy recovery assembly may affect selectivity as a result of increased pressure in the decomposition coil of the furnace assembly, and may change the selectivity of the decomposition reaction within the furnace assembly 100. Regarding residence time, the longer the residence time, the more likely it is to cause further side reactions in the thermal energy recovery assembly 110 or 1000.

[0102] In some embodiments of the present disclosure, the thermal energy recovery assemblies 110 or 1000 may be configured to preheat the high-temperature reactor effluent or product gas by using the reaction material as a cooling medium for the high-temperature reactor effluent, for example, and preheating the material with the high-temperature reactor effluent before it enters the reactor chamber 11. For example, as shown in Figure 1B, the thermal energy recovery assemblies 110 may receive the material through the low-temperature material pipeline 23 and provide the preheated material to the reaction chamber 11 through the reactor material pipeline 26. The thermal energy recovery assemblies 12 and 13 may receive the high-temperature reactor effluent from the reactor effluent pipeline 27 and provide the quenched reactor effluent to the quenched effluent pipeline 28.

[0103] In some embodiments, the thermal energy recovery assemblies 12 and 13 shown in Figures 1A to 1F may be configured to exchange heat from the high-temperature reactor effluent to the raw materials. As a result of heat exchange between multiple gases, it is more difficult to quench the reactor effluent within a desired residence time, for example, due to the generally lower heat transfer coefficient and lower temperature difference between the high-temperature and low-temperature fluids of gas-gas exchangers, compared to liquid-gas heat exchangers (e.g., steam-generating heat exchangers that use boiling water as a relatively low-temperature cooling medium, typically used with gas combustion cracking furnaces). Therefore, further design features for the thermal energy recovery assemblies 110 or 1000 may be desirable, as described in some of the exemplary embodiments below.

[0104] Referring to Figures 2A and 2B, a portion of the exemplary thermal energy recovery assembly 1000 is shown having a passage-in-passage design, in which high-temperature reactor effluent or product gas P flows through an inner passage 1034 (e.g., a central passage), and reaction raw materials F flow through an outer ring 1044 which is at least partially defined by the inner passage 1034 and the outer passage 1040. As shown, the inner passage 1034 is arranged around the central axis of the thermal energy recovery assembly 1000. In some embodiments, the inner passage 1034 may be arranged off-center from the central axis of the thermal energy recovery assembly 1000.

[0105] The thermal energy recovery assembly 1000 may be a parallel-flow heat exchanger or (for example, as shown) a counter-flow heat exchanger, and the high-temperature reactor effluent or product gas P flows through the thermal energy recovery assembly 1000 in a first direction, and the raw material F flows through the thermal energy recovery assembly 1000 in a second direction opposite to the first direction. In some embodiments, the inner passage 1034 may include an inlet 1033 and an outlet 1035, and the high-temperature reactor effluent or product gas P enters through the inlet 1033, flows through the inner passage 1034, and exits through the outlet 1035. The ring 1044 may include an inlet 1043 and an outlet 1045, and the reaction raw material F enters through the inlet 1043, flows through the ring 1044, and exits through the outlet 1045 as preheated reaction raw material F.

[0106] In such embodiments, the high-temperature reactor effluent or product gas P enters the thermal energy recovery assembly 1000 at inlet 1033 at its highest temperature before being cooled by heat transfer to the reaction raw materials F in order to preheat the reaction raw materials F. Inlet 1033 is adjacent to the point where the raw materials, after being heated by the reactor effluent, exit the thermal energy recovery assembly 1000 through outlet 1045 as preheated raw materials at their highest temperature. The reactor effluent or product gas P (e.g., rapidly cooled reactor effluent) exits the thermal energy recovery assembly 1000 at outlet 1035 at its lowest temperature after heating the raw materials. Outlet 1035 is adjacent to the point where the reaction raw materials F enter the thermal energy recovery assembly 1000 through inlet 1043 at their lowest temperature before being heated by the high-temperature reactor effluent or product gas P.

[0107] In some such embodiments, the high-temperature reactor effluent or product gas P enters the thermal energy recovery assembly 1000 at its highest temperature at the point where the reaction material F exits the thermal energy recovery assembly 1000 at its highest temperature, and the reactor effluent or product gas P exits the thermal energy recovery assembly 1000 at its lowest temperature at the point where the material enters the thermal energy recovery assembly 1000 at its lowest temperature. In some embodiments, the thermal energy recovery assembly 1000 may be a counterflow heat exchanger, and the reactor effluent or product gas P and the reaction material F flow in the same direction within the thermal energy recovery assembly 1000. In some embodiments, if the thermal energy recovery assembly 1000 consists of two or more stages, some stages may be parallel flow and others counterflow.

[0108] In some embodiments, the inner passage 1034 may be or may include a bare tube or a simple tube having a smooth inner surface. In some embodiments, the inner passage 1034 may include heat transfer enhancers or reinforcing structures (these terms are used hereafter as synonyms) that promote turbulence or increase the surface area of ​​the inner passage 1034. For example, the inner passage 1034 may include velocity rods or other turbulence-promoting structures. In some embodiments, the inner passage 1034 may include fins (e.g., straight fins and / or spiral fins, rectangular and / or round cross-sections) or other surfaces that increase the contact surface area with the reactor effluent or product gas P flowing through the inner passage 1034. Such heat transfer enhancers in the inner passage 1034 may reduce the residence time of the reactor effluent or product gas P. The heat transfer enhancers may increase the pressure drop in the reactor effluent or product gas P. In some embodiments, the inner passage 1034 may include a heat transfer enhancement section to balance the pressure drop that may originate from the heat transfer enhancement section, for example. In some embodiments, fouling may be expected, which may require frequent cleaning of the inner passage 1034. In such embodiments, the inner passage 1034 may be a straight or bare pipe to facilitate cleaning. In certain embodiments, the section of the inner passage 1034 may be a bare pipe, and the section of the inner passage 1034 may include a heat transfer enhancement section such as the turbulence-enhancing structure and / or area-increasing feature described above.

[0109] In some embodiments, the ring 1044 may include turbulence-enhancing structures such as winglets, artificial roughness, washboards / grooves, pin fins, and / or depressions. Such structures can increase the heat transfer coefficient from the outer surface of the inner passage 1034 and / or increase the pressure drop of the reactant F moving through the ring 1044. Such structures can be used as heat transfer enhancing structures on their own or in combination with other heat transfer enhancing structures such as plates and piccolo impactors described herein.

[0110] In some embodiments, the outer ring 1044 may include a high-shear inductive shape configured to promote a high-shear flow, which may result from a fast-flowing material, such as more than 50 meters per second (m / s), or more than 60 m / s, or more than 70 m / s, or more than 80 m / s. In some embodiments, the direction of the high-shear material flow through the outer passage is substantially parallel to the inner passage. In some embodiments, the high-shear inductive shape may include configuring the outer passage such that the gap between the outer surface of the inner passage 34 and the inner surface of the outer passage is 10 millimeters (mm) or less, 8 mm or less, 6 mm or less, or 4 mm or less. The high shear rate can act as a heat transfer enhancer by promoting a high heat transfer rate from the reactant material F to the outer surface of the inner passage 1034.

[0111] In some embodiments, the heat transfer enhancement portion due to collision may refer to a fluid flow passing through an outer passage, and the average direction of the fluid flow as it moves from the inlet to the outlet may be substantially parallel to the inner passage, for example, intentionally guided toward the inner passage using a geometric feature introduced into the outer passage. In some embodiments, this guided (collision) flow may be perpendicular to the inner passage, or directed toward the inner passage at an angle greater than 30 degrees with respect to the axis of the inner passage, while the velocity of the guided flow may be relatively greater than the surface velocity of the outer passage flow (e.g., the volumetric flow rate of the outer passage flow divided by the annular cross-sectional region between the inner and outer passages). In some embodiments, the geometric feature that facilitates collision may include, for example, nozzles and / or openings directed toward the inner passage, and / or obstacles placed in a channel that can redirect the fluid toward the inner passage from a more parallel direction, directly toward the outer surface of the inner passage. These exemplary features may be implemented in a periodic manner, resulting in collision zones occurring at multiple intervals along the length and / or circumference of the inner passage, for example. The applicant found that introducing such impingement features can increase the heat transfer coefficient compared to the heat transfer coefficient obtained by parallel flow through the outer passage. Furthermore, the applicant found that, with respect to an appropriate level of heat transfer enhancement, the ratio of impingement flow velocity to surface velocity can exceed 2, exceed 5, or exceed 10. The velocity of the impingement flow can be approximated, in the case of a nozzle or opening, as a volumetric flow rate divided by the total flow area defined by the nozzle or opening through which the flow is induced.

[0112] Furthermore, it can be found that the heat transfer enhancement section is more suitable at a certain distance between the collision induction feature (e.g., nozzle or opening 1054) and the inner passage, where this distance is from approximately equal to the diameter of the nozzle or opening 1054 to about 12 times the diameter, from approximately equal to the diameter to about 10 times the diameter, or from about 2 times the diameter to about 8 times the diameter. Examples of collision features may include plate collision sections and / or piccolo collision sections. In some embodiments, at least one heat transfer enhancement section in the first stage may be the same as or different from at least one heat transfer enhancement section in the second stage.

[0113] Next, referring again to Figures 2A, 2B, 3A, and 3B, the outer ring 1044 of the thermal energy recovery assembly 1000 (Figures 2A and 2B) may include one or more structural components that facilitate heat transfer from the reactor effluent or product gas P in the inner passage 1034 of the thermal energy recovery assembly 1000 to the reaction material F in the outer passage 1044. For example, the thermal energy recovery assembly 1000 may include a plate impact section 1050 within the outer ring 1044 of the thermal energy recovery assembly 1000, as shown, for example, in Figures 2A and 2B, and / or the thermal energy recovery assembly 1000 may include a piccolo impact section 1060 (see also Figure 3A) within the outer ring 1044 of the thermal energy recovery assembly 1000 (see also Figure 3B).

[0114] Referring particularly to Figures 2A and 2B, the plate impact section 1050 may contain a cooling medium (e.g., reaction material F) entering the first flow path 1052 via a step inlet 1043, the step inlet 1043 may be spaced apart from the inner passage 1034, for example, on the outside or outer periphery of the outer ring 1044 of the thermal energy recovery assembly 1000. The cooling medium exits the first flow path through one or more nozzles or openings in the wall 1055 and reaches a second flow path 1056 that contacts the inner passage 1034. The first flow path 1052 may terminate at a downstream end 1058, for example, so that the cooling medium is propelled into the second flow path 1056, flows through the outer passage 1044, and exits the step outlet 1045 at the downstream end of the second flow path 1056. The wall 1055 separates the first flow path 1052 from the second flow path 1056. The thermal energy recovery assembly 1000 may include one or more plate impact sections 1050 arranged along the length of the thermal energy recovery assembly 1000. Each plate impact section 1050 shown in Figures 2A and 2B may be considered a plate impact stage, and the thermal energy recovery assembly 1000 may include one or more impact stages in series or in parallel.

[0115] In some embodiments, one or more nozzles or openings 1054 may have a circular cross-section. In some such embodiments, the diameter of one or more nozzles or openings 1054 may range from about 1 millimeter (mm) to about 15 mm, for example, from about 2 mm to about 10 mm, from about 3 mm to about 8 mm, or from about 4 mm to about 7 mm. In nozzles or openings 1054 that do not have a circular cross-section, the cross-sectional area of ​​the nozzle or opening 1054 may substantially correspond to the area of ​​a nozzle or opening 1054 that has a circular cross-section. In some embodiments, the nozzles or openings 1054 may be circumferentially aligned at various points along the longitudinal length of the wall 1055, or the nozzles or openings 1054 may be circumferentially staggered along the longitudinal length of the wall, for example, in a spiral manner. In some embodiments, the wall 1055 may be spaced apart from the outer surface of the inner passage 1034 at distances ranging from approximately equal to the diameter of the nozzle or opening 1054 to 12 times the diameter of the nozzle or opening 1054, or from the distance of the diameter to about 10 times the diameter, or from about 2 times the diameter to about 8 times the diameter, for example, when the nozzle or opening 1054 has a circular cross-section.

[0116] In some embodiments, the nozzles or openings 1054 may be spaced apart around the circumference of the wall 1055. For example, at a given point along the longitudinal length of the wall 1055, the wall may contain, for example, 1 to 15 nozzles or openings 1054, and may depend at least in part on the dimensions of the inner passage 1034, for example, having relatively more nozzles or openings 54 for a relatively larger inner passage 1034. In some embodiments, the nozzles or openings 1054 may be spaced apart circumferentially around the inner passage 1034, for example, the spacing being equal to pi (i.e., 3.14159) multiplied by the sum of the diameter of the outer surface of the inner passage 1034 and twice the distance from the nozzle or opening 1054 to the outer surface of the inner passage 1034, and all of these divided by the number of nozzles or openings 1054 around the circumference. In some embodiments, the nozzles or openings 1054 may be substantially equal in distance from one another along the longitudinal length of the wall 1055 and / or substantially equal in the circumferential direction around the wall 1055.

[0117] Referring to Figures 3A and 3B, the piccolo impact section 1060 may include one or more piccolos or outer passages 1062 into which a cooling medium (e.g., raw material) is contained, and a chamber 1066 defined around an inner passage 1034. In some embodiments, the chamber 1066 may generally define an outer passage, such as the outer passage or ring 1044 shown in Figures 2A and 2B. The outer passage 1062 may include a stepped inlet 1043 and may include one or more nozzles or openings 1064 configured to allow the cooling medium to flow from the outer passage 1062 into the chamber 1066, for example, to bring the cooling medium into contact with the inner passage 1034. In some embodiments, one or more of the nozzles or openings 1064 may be guided on the outer surface of the inner passage 1034, for example, as shown in Figure 3B. Chamber 1066 may be defined between a first upstream divider 1065 and a second downstream divider 1067. The upstream divider 1065 may include an opening that allows the cooling medium to enter the outer passage 1062. The downstream divider 1067 may terminate at each downstream end of the outer passage 1062 and may include an outlet defined within the downstream divider 1067 that allows the cooling medium to exit Chamber 1066 and flow into another set of the outer passage 1062 or exit the thermal energy recovery assembly 1000. The thermal energy recovery assembly 1000 may include one or more piccolo impact sections 1060 arranged along the length of the thermal energy recovery assembly 1000. Each piccolo impact section 1060 shown in Figures 3A and 3B may be considered a piccolo impact stage, and the thermal energy recovery assembly 1000 may include one or more piccolo impact sections in series or in parallel with each other.

[0118] In some embodiments, one or more nozzles or openings 1064 may have a circular cross-section. In some such embodiments, the diameter of one or more nozzles or openings 1064 may range from about 1 millimeter (mm) to about 15 mm, for example, from about 2 mm to about 10 mm, from about 3 mm to about 8 mm, or from about 4 mm to about 7 mm. In nozzles or openings 1064 that do not have a circular cross-section, the cross-sectional area of ​​the nozzle or opening 1064 may substantially correspond to the area of ​​a nozzle or opening 1064 that has a circular cross-section. In some embodiments, the nozzles or openings 1064 may be circumferentially aligned with respect to their respective outer passages 1062, and the fluid passing through each of the nozzles or openings 1064 is guided to the outer surface of the inner passage 1034 at an angle of about 90 degrees with respect to the outer surface of the inner passage 1034. In some embodiments, one or more nozzles or openings 1064 may be circumferentially oriented with respect to each outer passage 1062, such that the fluid passing through the nozzles or openings 1064 is at a non-orthogonal angle with respect to the outer surface of the inner passage 1034, with non-orthogonal angles ranging, for example, from about 10 to about 80 degrees, 20 to about 80 degrees, 30 to about 80 degrees, or from about 45 to about 80 degrees. In some embodiments, the nozzles or openings 1064 may be positioned at various points along the length of the outer passage 1062 (for example, along the longitudinal axis) and aligned circumferentially. In some embodiments, the nozzle or opening 1064 may be spaced apart from the outer surface of the inner passage 1034 at distances ranging from approximately equal to the diameter of the nozzle or opening 1064 to approximately 12 times the diameter of the nozzle or opening 1064, or from approximately equal to the diameter to approximately 10 times the diameter, or from approximately 2 times the diameter to approximately 8 times the diameter, for example, if the nozzle or opening 1064 has a circular cross-section.

[0119] In some embodiments, each of the outer passages 1062 may include a single nozzle or opening 1064 at each of several locations along the length of the outer passage 1062. In some embodiments, each of the outer passages 1062 may include 1 to 15 nozzles or openings 1064, 1 to 10 nozzles or openings 1064, 1 to 5 nozzles or openings 1064 (e.g., 4 nozzles or openings 1064), or several nozzles or openings 1064 extending to 5 to 10 nozzles or openings 1064. In some embodiments, for example, the distance between nozzles or openings 1064 on each outer passage 1062 may be defined such that the distance between adjacent nozzles or openings 1064 is between 1 and 20, divided by the diameter of the nozzle or opening 1064. The number of outer passages 1062 in a single stage may be between 1 and 12, or between 2 and 6.

[0120] The thermal energy recovery assembly 1000 in Figures 2A and 2B may have a modular design with multiple stages along the length of the thermal energy recovery assembly 1000. For example, the thermal energy recovery assembly 1000 may include one or more impact stages 1050 and one or more piccolo impact stages 1060. In some embodiments, the thermal energy recovery assembly 1030 may include only one or more impact stages 1050, or only one or more piccolo impact stages 1060. In certain embodiments, the thermal energy recovery assembly 1000 may include a plate impact stage 1050, a piccolo impact stage 1060, and a turbulence-promoting (TP) feature or turbulence-promoting stage.

[0121] The thermal energy recovery assembly 1000 shown in Figures 2A and 2B can be used in conjunction with a conventional gas-liquid vapor rise TLE. For example, a conventional TLE can be used to perform the initial quenching of the reactor effluent, and then the thermal energy recovery assembly 1000 can be used as long as the reactor effluent enters the thermal energy recovery assembly 1000 at a temperature of at least 550°C, at least 575°C, at least 600°C, at least 610°C, at least 620°C, at least 630°C, at least 640°C, at least 650°C, at least 700°C, at least 750°C, or at least 800°C, or at least 850°C. Alternatively, a conventional TLE may follow the thermal energy recovery assembly 1000, for example, if the thermal energy recovery assembly 1000 preheats the raw materials to at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least 450°C, at least 475°C, at least 500°C, at least 525°C, at least 550°C, at least 575°C, at least 600°C, at least 625°C, or at least 650°C. For example, a combustion cracking furnace assembly may include a conventional TLE before or after the thermal energy recovery assembly 1000. For example, a reactor effluent pipeline and / or quenching effluent pipeline may include a conventional TLE. In some embodiments, a conventional gas-liquid vapor rise TLE may be part of the same assembly as the thermal energy recovery assembly 1000. In some embodiments, the thermal energy recovery assembly 1000 according to some embodiments may be combined with superheating of the vapor flow.

[0122] The characteristics of the steps of the thermal energy recovery assembly 1000 in Figures 2A and 2B can be adjusted, for example, depending on the position of the steps within the thermal energy recovery assembly 1000. For example, if the thermal energy recovery assembly 1000 includes a plate impact step 1050, the passages 1052 and / or 1056, the nozzle or opening 1054, and / or the length of the plate impact step 1050 can be sized and dimensionally determined to optimize heat transfer under the conditions at that position along the thermal energy recovery assembly 1000. Thus, the first passage 1056 of the step 1050 at a first position along the thermal energy recovery assembly 1030 may have a higher radial height than the first passage 1056 of the step 1050 at a second position along the thermal energy recovery assembly 1000. Similarly, the nozzle or opening 1054 of the step 1050 at a first position may have a smaller diameter than the nozzle or opening 1054 of the step 1050 at a second position. In some embodiments, the radial height may remain substantially equal between one or more stages. In some embodiments, if the thermal energy recovery assembly 1000 includes a piccolo impact stage 1060, the diameter of the outer passage 1062, the size and / or number of nozzles 1064, and / or the length of the piccolo impact stage 1060 may be sized and dimensional to optimize heat transfer under the conditions at that location along the thermal energy recovery assembly 1030. In some embodiments, the number of nozzles or openings 1054 between stages may be more, fewer, or the same. In some embodiments, the number of rows of nozzles or openings 1054 may vary from stage to stage. The conditions along the thermal energy recovery assembly 1030 may include the temperature of the reactor effluent, the temperature of the raw materials, the inlet and / or outlet pressure of the reactor effluent, the inlet and / or outlet pressure of the raw materials, the pressure drop of the reactor effluent along the length of the assembly pressure, the pressure drop of the raw materials along the length of the thermal energy recovery assembly 1000, the temperature difference between the raw materials and the reactor effluent, the velocity of the reactor effluent, and / or the velocity of the raw materials.

[0123] As described above, the thermal energy recovery assembly may include multiple stages that are parallel to each other. The thermal energy recovery assembly 1000 may enable or disable one or more of these parallel stages based on the temperature of the high-temperature reactor effluent entering the thermal energy recovery assembly 1000, or the temperature of the quenched reactor effluent leaving the thermal energy recovery assembly 1000. When a stage is enabled, the high-temperature reactor effluent flows through the stage, and when a stage is disabled, the high-temperature reactor effluent is prevented from flowing through the stage. For example, if the quenched reactor effluent leaving the thermal energy recovery assembly 1000 is above a desired temperature, the thermal energy recovery assembly 1000 may enable another one or more stages, and if the quenched reactor effluent or product gas P leaving the thermal energy recovery assembly 1000 is below a desired temperature, the thermal energy recovery assembly 1000 may disable one or more stages.

[0124] As described above, the thermal energy recovery assembly 1000 may include stages that are in series with respect to each other. The thermal energy recovery assembly 1000 may enable or disable one or more of these stages based, for example, on the temperature of the high-temperature reactor effluent entering the thermal energy recovery assembly 1000, the temperature of the rapidly cooling reactor effluent leaving the thermal energy recovery assembly 1000, the temperature of the raw materials entering the thermal energy recovery assembly 1000, and / or the temperature of the raw materials leaving the thermal energy recovery assembly 1000. In some embodiments, enabling a stage allows the raw materials to flow through the enabled stage, and disabling a stage prevents the raw materials from flowing through the disabled stage. For example, if the rapidly cooled reactor effluent leaving the thermal energy recovery assembly 1000 is above a desired temperature, the thermal energy recovery assembly 1000 enables one or more further stages to allow the temperature of the rapidly cooled reactor effluent leaving the thermal energy recovery assembly 1000 to decrease toward the desired temperature, and / or if the rapidly cooled reactor effluent leaving the thermal energy recovery assembly 1000 is below the desired temperature, the thermal energy recovery assembly 1000 disables one or more further stages to allow the temperature of the rapidly cooled reactor effluent leaving the thermal energy recovery assembly 1000 to increase toward the desired temperature. In some embodiments, the thermal energy recovery assembly 1000 may include one or more controllers configured to control the operation of one or more stages, for example, as understood by those skilled in the art. For example, the thermal energy recovery assembly 1000 may include a plurality of temperature sensors, pressure sensors, flow sensors, etc., which communicate with a controller, and the controller may use control logic in the form of computer software and / or hardware programs that make control decisions associated with the control operation of the thermal energy recovery assembly 1000, which includes, for example, one or more stages. In some embodiments, the thermal energy recovery assembly 1000 may include a valve associated with a pipeline and / or conduit, and the controller may transmit control signals to an actuator associated with the valve, at least in part based on control decisions, to control the flow of a fluid (e.g., gas and / or liquid) and / or heat, and the actuator may operate in accordance with the transmitted control signals to operate a part of the thermal energy recovery assembly 1000.In some examples, the controller may complement or replace a human operator who manually controls the thermal energy recovery assembly 1000 at least partially, based at least partially on efficiency considerations, to meet desired parameters.

[0125] In some embodiments, the thermal energy recovery assembly 1000 shown in Figures 2A to 3B may be configured to quench the high-temperature reactor effluent within residence times consistent with other quenching devices in a gas combustion cracking furnace and / or with a pressure drop. In some embodiments, the thermal energy recovery assembly 1000 may be adjusted or optimized to be substantially equivalent to or an improvement over other types of quenching devices. For example, the thermal energy recovery assembly 1000 may be configured such that the residence time measured by time within the thermal energy recovery assembly 1000 is less than 100 milliseconds (ms), e.g., less than 90 ms or less than 85 ms (e.g., less than 83 ms), the pressure drop of the reactor effluent is less than 0.35 bar, e.g., less than 0.30 bar, less than 0.25 bar or less than 0.20 bar (e.g., less than 0.15 bar), and / or the cooling rate is greater than 2.5 Kelvin (K) / ms, e.g., greater than 3.5 K / ms, greater than 4.0 K / ms, greater than 4.5 K / ms, at least 5 K / ms, or at least 5.5 K / ms, the cooling rate may be defined as the inlet temperature (in K degrees) of the high-temperature reactor effluent minus 923 K and divided by the residence time required to cool the high-temperature reactor effluent from its temperature to 923 K. The above applies except when the inlet temperature (in K degrees) of the high-temperature reactor effluent is less than 923K, or when the temperature of the cooled reactor effluent exceeds 923K. In this case, the cooling rate may be defined as the inlet temperature (in K degrees) of the high-temperature reactor effluent minus the temperature of the cooled reactor effluent as it leaves the thermal energy recovery assembly, divided by the residence time of the effluent within the assembly. In addition to the pressure drop and cooling rate performance on the effluent side, the thermal energy recovery assembly 1000 may be configured to achieve a pressure drop of 2 to 15 bar, for example, 2.5 to 10 bar, 3 to 8 bar, 3 to 10 bar, or 4 to 9 bar (for example, 5 to 8 bar) of the raw material, thereby managing the amount of pressurization required before the reaction raw material F enters the thermal energy recovery assembly 1000, while promoting a sufficiently high heat transfer rate from the inner passage to the raw material. The upper and lower temperature levels have already been described above.

[0126] In some embodiments, the thermal energy recovery assembly 1000 may be configured and / or controlled to rapidly cool the high-temperature reactor effluent or product gas P and to preheat the reaction material F to the reaction material temperature. For example, the thermal energy recovery assembly 1000 may be configured to transfer heat from the high-temperature reactor effluent to the reaction material in one or more stages, which may not be preheated or may not be preheated at all to supply to the decomposition furnace for decomposition. In some embodiments, the stages may have an inner-passage design, with the high-temperature reactor effluent or product gas P flowing through the inner passage and the reaction material F flowing through the outer passage. The outer passage may include stages having heat transfer enhancing features, such as plate impact sections, piccolo impact sections, one or more turbulence-enhancing features associated with the outer and / or inner passage, and / or surface area-enhancing features associated with the outer and / or inner passage. For example, the inner passage may include one or more heat transfer enhancing features configured to facilitate heat transfer from the high-temperature reactor effluent or product gas P. Configuring one or more stages and internal passages may involve selecting stages to transfer heat to the low-temperature reaction material F while achieving desired properties of the high-temperature reactor effluent or product gas P. For example, stages may be selected to improve or maximize the cooling rate of the high-temperature reactor effluent, improve or minimize the pressure drop of the high-temperature reactor effluent, improve or minimize the residence time of the high-temperature reactor effluent, and / or improve or minimize the pressure drop of the reaction material.

[0127] In some embodiments, the thermal energy recovery assembly may include a plurality of parallel inner passages, each inner passage located within an outer passage, and each outer passage having one or more heat transfer enhancing sections to enhance heat transfer from the inner passages to the outer passage as defined within the outer passage.

[0128] Figure 4A is a schematic cross-sectional view of an exemplary inner passage 1034a, including exemplary round protrusions 1070a on the inner surface 1072a of the inner passage 1034a, according to an embodiment of the present disclosure. As shown in Figure 4A, in some embodiments, the inner surface 1072a of the inner passage 1034a may include turbulence-enhancing structures and / or structures that increase the surface area of ​​the inner surface 1072a. For example, as shown in Figure 4A, the inner surface 1072a of the inner passage 1034a may include one or more round protrusions 1070a. In some embodiments, one or more round protrusions 1070a may extend toward the center of the inner passage 1034a and / or extend longitudinally, partially, intermittently, or completely along the length of the inner passage 1034a. In some embodiments, the round protrusions 1070a may be the same as or different from one another. In some embodiments, one or more rounded projections 1070a extend helically along the longitudinal length of the inner passage 1034a, for example, to promote vortices in the flow through the inner passage 1034a. In some embodiments, the projections on the inner surface of the inner passage 1034a may have a non-rounded configuration.

[0129] For example, Figure 4B is a schematic cross-sectional view of another exemplary inner passage 1034b, which includes exemplary rectangular projections 1070b on the inner surface 1072b of the inner passage 1034a, according to an embodiment of the present disclosure. In some embodiments, the inner surface of the inner passage 1034 may include a combination of round and rectangular projections.

[0130] Other configurations of the protrusions are considered. In some embodiments, the inner passage 1034 may include turbulence-enhancing structures and / or structures that increase the surface area of ​​the outer surface of the inner passage 1034. For example, the turbulence-enhancing structures and / or structures that increase the surface area of ​​the outer surface of the inner passage 1034 may include protrusions on the inner surface of the inner passage 1034 that are at least similar to the protrusions described above. In some embodiments, the structures that increase the surface area of ​​the outer surface of the inner passage 1034 may be configured to enhance the effect of the turbulence-enhancing structures and / or impact features. In some embodiments, the inner surface of the outer passage 1040 may include surface area-enhancing structures, such as those described above.

[0131] Figure 5 is a block diagram of an exemplary method 2000 for heating reaction materials, the materials including, for example, one or more of ethane, propane, butane, condensates, light naphtha, heavy naphtha, diesel fuel, pyrolysis oil, materials derived from processing and refining flows, Fischer-Tropsch products, plastic waste and / or biological materials. The materials may further include steam. The reaction materials may be preheated in a high-efficiency, low-emission combustion cracking furnace capable of producing decomposed hydrocarbons including olefins, and then decomposed.

[0132] Figure 5 shows an exemplary method 200 as a collection of blocks of a logical flow graph representing a sequence of operations, according to several embodiments. The order in which the operations are described is not intended to be interpreted as limiting, and any number of described blocks may be combined in any order and / or in parallel to carry out the method. Furthermore, operations described in one or more blocks, such as the operations described by blocks 2012 and / or 2014, may be optional and / or omitted from exemplary method 2000, while one or more operations described by other blocks may be omitted from exemplary method 2000, either further or alternatively.

[0133] Exemplary method 2000 may include, in 2002, supplying hydrocarbons or reaction materials to an outer passage of the thermal energy recovery assembly. For example, the thermal energy recovery system may include any thermal energy recovery system described herein. As described above, the reaction materials may include, for example, one or more of ethane, propane, butane, condensates, light naphtha, heavy naphtha, diesel fuel, pyrolysis oil, and / or materials derived from processing and refining flows, Fischer-Tropsch products, plastic waste, or biological raw materials, or any other hydrocarbons that can be converted to olefins in a decomposition process, and may further include vapors. In some embodiments, the reaction materials may include or be the reaction materials supplied by a reaction material supply source.

[0134] In 2004, exemplary method 2000 may further include heating the reaction material in an outer passage of a thermal energy recovery assembly and outputting the preheated reaction material. For example, as described herein, the reaction material may be preheated via heat transfer within a thermal energy recovery system, and the thermal energy is supplied at least partially by the high-temperature reactor effluent of the decomposition step.

[0135] Exemplary method 2000 may also include, in 2006, supplying preheated reaction materials to a high-efficiency low-emission combustion cracking furnace, which includes, for example, a reaction area for heating the preheated reaction materials, as previously described.

[0136] In 2008, exemplary method 500 may further include, as described above, decomposing the reaction materials preheated in the reaction area to produce, for example, a high-temperature reactor effluent containing decomposed hydrocarbons and olefins.

[0137] Exemplary method 2000 may also include, in 2010, supplying high-temperature reactor effluent to the internal passage of the thermal energy recovery assembly, for example, as previously described. For example, in some embodiments, supplying high-temperature reactor effluent to the internal passage of the thermal energy recovery assembly may include supplying the high-temperature reactor effluent to the internal passage of the thermal energy recovery assembly at a temperature of at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least 450°C, at least 475°C, at least 500°C, at least 525°C, at least 550°C, at least 575°C, at least 600°C, at least 625°C, at least 650°C, at least 700°C, at least 750°C, at least 800°C, or at least 850°C.

[0138] In 512, the exemplary method 2000 may further include supplying additional raw materials to the outer passage of the thermal energy recovery assembly. The additional raw materials may, in some embodiments, be a series of feeds of reactants from the reactant source in 2002, different reactants, water, or steam. The additional raw materials may be supplied to a stage different from the stage to which the reactants are supplied. The additional raw materials may be mixed with the reactants, and the mixed raw materials exit the thermal energy recovery assembly at a common outlet. The additional raw materials may traverse a stage different from the stage to which the reactants traverse and exit through a different outlet.

[0139] Exemplary method 2000, in 2014, may also include heating further reactants by transferring heat from the high-temperature reactor effluent to them via a thermal energy recovery assembly, for example, as previously described. Heating further reactants in the outer passage of the thermal energy recovery assembly to produce preheated reactants may include heating the reactants to a temperature of at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least 450°C, at least 475°C, at least 500°C, at least 525°C, at least 550°C, at least 575°C, at least 600°C, at least 625°C, or at least 650°C. In some embodiments, supplying the high-temperature reactor effluent to the inner passage of the thermal energy recovery assembly may include quenching the high-temperature reactor effluent via heat transfer to further reactants, for example, as described herein. In some embodiments, heating the reactants in the outer passage of the thermal energy recovery assembly may include preheating the reactants via heat transfer from the high-temperature reactor effluent to the reactants. In some embodiments, the exemplary method 2000 may further include enhancing heat transfer to additional raw materials by providing a heat transfer enhancing section on one or more of the outer or inner passages. The heat transfer enhancing section may include, for example, one or more plate impact sections, piccolo impact sections, turbulence enhancing sections, or surface area increasing sections, as previously described.

[0140] In 2016, exemplary method 2000 may include the use of flue gas heat in a convection area to preheat the oxidizer in one or more steps. Furthermore, heat may be used indirectly in the form of steam from the quenching of high-temperature reactor effluent or heated boiler feedwater in addition to the oxidizer preheating.

[0141] In 2018, Exemplary Method 2000 may further include burning a preheated oxidizer with hydrogen or a hydrogen-enriched fuel gas in a combustion cracking furnace.

[0142] Referring to Figures 6 and 7, which relate to a single-stage application of an in-passage gas-gas exchanger within an energy recovery assembly, the reactor effluent or product gas may be either counterflowing (Figure 6) or parallel flowing (Figure 7) with respect to the reactants. The product gas inlet is indicated by 1, while the product gas outlet is indicated by 2. The reactants inlet is indicated by 3, while the reactants outlet is indicated by 4. As previously described, the high-temperature reactor effluent or product gas is supplied to the inner passage, and the reactants are supplied to the outer passage, which is arranged around the inner passage to encircle the ring. The outer passage may include at least one heat transfer enhancing section that enhances heat transfer from the inner passage to the outer passage through collision, turbulence enhancement, high-shear induction geometry, or surface area enhancement sections.

[0143] Referring to Figures 8 and 9, which illustrate a two-stage application of an in-passage gas-gas exchanger within an energy recovery assembly, the flow direction of the reactor effluent or product gas may be parallel to the feedstock in the first stage and counterflow relative to the feedstock in the second stage. Again, the product gas inlet is indicated by 1, while the product gas outlet is indicated by 2. The reaction feedstock inlet is indicated by 3, while the reaction feedstock outlet is indicated by 4. As previously described, the high-temperature reactor effluent or product gas is supplied to the inner passage, and the reaction feedstock is supplied to the outer passage, which is arranged around the inner passage so as to surround one outer passage. The outer passage may include at least one heat transfer enhancement section that enhances heat transfer from the inner passage to the outer passage through collision, turbulence enhancement, high-shear induction geometry, or surface area increase sections. The heat transfer enhancement method and detailed layout applied may be the same or different in both stages.

[0144] In some embodiments of the two-stage application, the low-temperature reaction material may enter the inner-passage gas-gas exchanger in the co-flow stage where the first preheating takes place, and may be further heated in the counterflow stage (Figure 8). As previously described, the high-temperature reactor effluent or product gas is supplied to the inner passage, and the reaction material is supplied to the outer passage, which is arranged around the inner passage so as to surround one outer passage. The outer passage may include at least one heat transfer enhancing section that enhances heat transfer from the inner passage to the outer passage through collision, turbulence promotion, high-shear induction geometry, or surface area increase sections. The heat transfer enhancing method and detailed layout applied may be the same or different in both stages.

[0145] In some embodiments of the two-stage application, the low-temperature reaction material may enter the inner-passage gas-gas exchanger in the counterflow stage where the first preheating takes place, and may be further heated in the parallel-flow stage (Figure 9). As previously described, the high-temperature reactor effluent or product gas is supplied to the inner passage, and the reaction material is supplied to the outer passage, which is arranged around the inner passage so as to surround one outer passage. The outer passage may include at least one heat transfer enhancing section that enhances heat transfer from the inner passage to the outer passage through collision, turbulence enhancement, high-shear induction geometry, or surface area enhancement sections. The heat transfer enhancing method and detailed layout applied may be the same or different in both stages.

[0146] In some embodiments, the countercurrent stage constitutes a separate thermal energy recovery assembly and can be constructed as a conventional passage-in-passage or shell-and-passage type heat exchanger.

[0147] Referring to Figure 10, which illustrates a two-stage application of an in-passage gas-gas exchanger within an energy recovery assembly, the flow direction of the reactor effluent or product gas may be parallel to the reactants in the first stage and parallel to the reactants in the second stage. Again, the product gas inlet is indicated by 1, while the product gas outlet is indicated by 2. The reactants inlet is indicated by 3, while the reactants outlet is indicated by 4. As previously described, the high-temperature reactor effluent or product gas is supplied to the inner passage, and the reactants are supplied to the outer passage, which is arranged around the inner passage so as to surround one outer passage. The outer passage may include at least one heat transfer enhancement section that enhances heat transfer from the inner passage to the outer passage through collision, turbulence enhancement, high-shear induction geometry, or surface area increase sections. The heat transfer enhancement method and detailed layout applied may be the same or different in both stages.

[0148] In some embodiments of the two-stage application, the low-temperature reaction material may enter the passage-in-passage gas-gas exchanger in the second parallel-flow stage where the first preheating takes place, as viewed from the reactor effluent or product gas flow, and may be further heated in the first parallel-flow stage (Figure 10). As previously described, the high-temperature reactor effluent or product gas is supplied to the inner passage, and the reaction material is supplied to the outer passage, which is arranged around the inner passage so as to surround one outer passage. As repeatedly shown, the outer passage may include at least one heat transfer enhancing section that enhances heat transfer from the inner passage to the outer passage through collision, turbulence enhancement, high-shear induction geometry, or surface area increase sections. The heat transfer enhancing method and detailed layout applied may be the same or different in both stages. [Examples]

[0149] Example 1 The heat transfer performance of several thermal energy recovery assemblies, including heat transfer reinforcement sections according to embodiments of the present disclosure, was compared with that of a conventional in-passage gas-gas heat exchanger. Conventional heat exchangers were designed to have a raw material pressure drop of 1.76 bar and did not include reinforcement sections in either the inner or outer passages. The thermal energy recovery assemblies according to embodiments of the present disclosure were configured as follows: (1) A thermal energy recovery assembly with a heat transfer enhancement section in the inner passage and a high shear shape in the outer passage; (2) A thermal energy recovery assembly with fins in the inner passage and a turbulence-enhancing feature section in the outer passage; (3) A thermal energy recovery assembly with fins in the inner passage and a plate impact section in the outer passage; (4) A thermal energy recovery assembly with fins in the inner passage and a piccolo impact section in the outer passage; (5) A thermal energy recovery assembly with a flat passage (without internal fins) and a turbulence-enhancing feature section in the outer passage; (6) A thermal energy recovery assembly with a flat passage and a plate impact section in the outer passage, and a thermal energy recovery assembly with a flat passage and a piccolo impact section in the outer passage.

[0150] For comparative purposes, boundary conditions for a conventional heat exchanger ("Comparative") and each of the seven exemplary thermal energy recovery assemblies (1 to 7) according to embodiments of the present disclosure were established as follows: the high-temperature effluent obtained from the vapor decomposition of ethane was passed through the inner passage, and the low-temperature feedstock containing ethane and vapor was passed through the outer passage. The mass flow rate of the high-temperature effluent was 351.6 kg / hour, the outer diameter of the inner passage was 60.3 mm, and the passage wall thickness was 3.6 mm. The high-temperature effluent and low-temperature feedstock provided in the counterflow configuration described above were subjected to the following inlet temperatures (T) for the high-temperature effluent and low-temperature feedstock. in ) and outlet temperature (T out ) has. According to this embodiment, T in,hot This is equal to 827℃, T out,hot This is equal to 486℃, T in,cold This is equal to 236℃, T out,cold This is equivalent to 650°C.

[0151] Using software tools designed for heat transfer calculations, we accessed the performance of a conventional heat exchanger ("Comparison") and seven embodiments according to the embodiments of this disclosure. Table A below shows the comparative performance in terms of various measurement criteria described below. For each measurement criterion, the respective values ​​for the thermal energy recovery assemblies (1 to 7) according to the embodiments of this disclosure are listed against the corresponding values ​​for the conventional heat exchanger. Exemplary metrics provided for comparison are effluent cooling rate, heated surface area, pressure drops on the raw material and effluent sides of the corresponding devices, and effluent residence time.

[0152] TIFF2026516193000002.tif140170Table A

[0153] As shown in Table A, the thermal energy recovery assemblies according to embodiments of the present disclosure may provide improved performance compared to heat exchangers without such heat transfer enhancements, for example, in terms of cooling rate, residence time, effluent pressure drop, and / or required cooling surface area. As is evident from the present disclosure, higher cooling rates and lower required surface area, effluent pressure drop, and effluent residence times may generally be advantageous in terms of process performance and / or equipment costs.

[0154] Examples 2(a) and 2(b) With respect to liquid and gaseous feedstocks, evidence of energy balance through process simulation software, and technical feasibility through furnace and equipment design, leads to the exemplary drawings in Figures 2a and 2b below, which illustrate levers for reducing combustion load and greenhouse gas emissions in the embodiments considered herein.

[0155] Example 2(a) is a comparative performance analysis of a high-efficiency, low-emission combustion steam cracking furnace, combined with a thermal energy recovery assembly according to the embodiment of the present disclosure shown in Figures 1A and 1C, processing 48 tons of naphtha per hour, compared to a conventional state-of-the-art cracking furnace without oxidizer preheating.

[0156] The following basic parameters were selected for comparison: • Naphtha raw material rate: 48 tons per hour, 70°C • Diluted vapor: 24 tons per hour, 190°C • Propylene-to-ethylene ratio: 0.45 (Decomposition severity) Fuel gas composition: 78% by weight hydrogen, 12% methane • Oxidizer in ambient air at 20°C • Steam conditions: 115 bar, 505°C.

[0157] The thermal energy recovery units 12 and 13 in Figures 1A and 1C are configured as a two-stage parallel / counterflow exchanger (B) (as shown in Figure 9) that allows heat from the available high-temperature reactor effluent to be transferred to the preheated raw material at a rate of 30% (2a-1) to 50% (2a-2) to 70% (2a-3). The combustion air is preheated externally to 300°C relative to the VHP steam and further heated within the convection zone of the combustion furnace. This allows for air preheating temperatures of up to 430°C (2a-1), 600°C (2a-2), or even 700°C (2a-3). The reduction in combustion load in the furnace combustor is 20% in Example 2a-1, 40% in Example 2a-2, and 45% in Example 2a-3. The net steam discharged from the furnace and thermal integration unit is reduced by more than 60% in 2a-1, approximately 80% in 2a-2, and approximately 90% in 2a-3. See Table B.

[0158] TIFF2026516193000003.tif85170Table B

[0159] Example 2(b) is a comparative performance analysis of a high-efficiency, low-emission combustion steam cracking furnace, combined with a thermal energy recovery assembly according to the embodiment shown in Figure 1D, processing 51 tons of ethane per hour, compared to a conventional, state-of-the-art cracking furnace that does not preheat the oxidizer.

[0160] The following basic parameters were selected for comparison: • Ethane raw material rate: 51 tons per hour, 70°C • Diluted vapor: 15.3 tons per hour, 190°C • Ethane conversion: 60% • Fuel gas composition: 100% by weight hydrogen • Oxidized material: Ambient air at 20°C • Steam conditions: Variable (115 bar, 505°C and 42 bar, 450°C)

[0161] In Figure 1D, the heat energy recovery units 12 and 13 are configured as a two-stage parallel / counterflow exchanger (B) that allows 30% (2b-1) to 50% (2a-2) of the heat from the available high-temperature reactor effluent to the preheated feedstock (as shown in Figure 9). Combustion air is preheated externally to approximately 250°C relative to the preheated boiler feedwater. The air is further heated in air preheaters I and II within the convection zone of the combustion furnace. Such a design can achieve air preheating temperatures of up to 600°C (2b-1) or even 780°C (2b-2). The reduction in combustion load in the furnace combustor is approximately 45% in total in Examples 2b-1 and 2b-2. Net steam discharged from the furnace and heat integration unit is reduced by more than 60% in Examples 2b-1 and 2b-2. See Table C below.

[0162] TIFF2026516193000004.tif105170Table C

[0163] Examples 3(a) to 3(c) Examples 3(a) to 3(c) relating to the ethane application case use a raw material-flue heat exchanger for primary cooling and steam generation for secondary cooling. Examples 3(a) to 3(c) differ in the configuration of the raw material-flue heat exchanger. Generally, Example 3(a) may essentially correspond to Figure 6, Example 3(b) may essentially correspond to Figure 8, and Example 3(c) may essentially correspond to Figure 9. In Example 3(a), the raw material-flue heat exchanger has one stage and is counterflow. In Examples 3(b) and 3(c), the raw material-flue heat exchanger has two stages, having a first co-flow stage and a second counterflow stage. In Example 3(b), the low-temperature raw material is first sent to the co-flow stage and then to the counterflow stage. In Example 3(c), the low-temperature raw material is first sent to the counterflow stage and then to the co-flow stage. In all three Examples 3(a) to 3(c), the reactor effluent flow and raw material flow are identical. In all three Examples 3(a) to 3(c), the raw materials are heated from 230°C to 580°C, and the reactor effluent is cooled from 849°C to 561°C. A summary of the results for Examples 3(a) to 3(c) is shown in Table D below, where the passage according to the corresponding embodiment is referred to as the “tube”. With the exception of the passage metal temperature, for each measurement criterion, the respective values ​​for Examples 3(a) to 3(c) are listed relative to the corresponding value for Example 3(a). Exemplary measurements provided for comparison are heat transfer, pressure drop inside the passage, effluent residence time, cooling rate, and required heating surface area.

[0164] The highest passage surface temperature in the inner passage is expected in Example 3(a), while the lowest inner passage surface temperature is expected in Example 3(b). As a result, the risk of entering a regime with increased coking due to premature decomposition on the outer surface of the passage and increased chemical coking on the inner surface of the passage is highest in the configuration represented by Example 3(a). The inner passage surface temperature obtained in Example 3(c) is between Examples 3(a) and 3(b), but closer to 3(b). At the low-temperature end of the assembly, the lowest temperature inside the passage is expected in Examples 3(a) and 3(c), while Example 3(b) exhibits a higher inner passage temperature. With respect to the ethane application examples shown herein, the risk of coking due to significant condensation is low.

[0165] Regarding the drop in effluent pressure inside the passage, which affects decomposition selectivity, Example 3(a) showed the lowest drop, followed by Example 3(c), and then Example 3(b) showed a significantly higher drop. The high drop in effluent pressure in Example 3(b) is due to the significantly longer passage length compared to Examples 3(a) and 3(c).

[0166] Regarding residence time and cooling rate, which refer to the cooling of the effluent up to a temperature of 650°C, favorable values ​​were obtained with the configuration of Example 3(b). This may be due to the maximum temperature difference at the effluent inlet between the effluent and the raw material.

[0167] However, given the equivalently high heat transfer surface required in Example 3(b) and the high passage metal temperature observed in Example 3(a), the configuration specified in Example 3(c) may be considered advantageous when the heat transfer surface is limited.

[0168] In general, those skilled in the art will select from the configurations of Examples 3(a) to 3(c) depending on the requirements given by specific technical and economic boundary conditions.

[0169] TIFF2026516193000005.tif71170Table D

[0170] Examples 4(a) to 4(c) In Examples 4(a) to 4(c) relating to naphtha application cases, a raw material-flue heat exchanger was used for primary cooling, and steam generation was used for secondary cooling. Examples 4(a) to 4(c) differ in the configuration of the raw material-flue heat exchanger. In Example 4(a), the raw material-flue heat exchanger had one stage and was in a counterflow configuration. In Examples 4(b) and 4(c), the raw material-flue heat exchanger had two stages, having a first parallel-flow stage and a second counterflow stage. In Example 4(b), the low-temperature raw material is first sent to the parallel-flow stage and then to the counterflow stage. In Example 4(c), the low-temperature raw material is first sent to the counterflow stage and then to the parallel-flow stage. In all three Examples 4(a) to 4(c), the reactor flue flow and raw material flow are identical. In all three Examples 3(a) to 3(c), the raw materials were heated from 223°C to 594°C, and the reactor effluent was cooled from 862°C to 539°C. A summary of the results for Examples 4(a) to 4(c) is shown in Table E below. With the exception of the passage metal temperature, for each measurement criterion, the respective values ​​for Examples 4(a) to 4(c) are listed relative to the corresponding values ​​for Example 4(a). Exemplary measurements provided for comparison are heat transfer, pressure drop inside the passage, effluent residence time, cooling rate, and required heating surface area.

[0171] The highest passage surface temperature in the inner passage is expected in Example 4(a), while the lowest inner passage surface temperature is expected in Example 4(b). As a result, the risk of entering a regime with increased coking due to premature decomposition on the outer passage surface and increased chemical coking on the inner passage surface is highest in the configuration represented by Example 4(a). The passage surface temperature obtained in Example 4(c) is between Examples 4(a) and 4(b), but closer to 4(b). At the low-temperature end of the assembly, the lowest temperature inside the passage is expected in Examples 4(a) and 4(c), while Example 4(b) exhibits a higher inner passage temperature. With respect to Examples 4(a) and 4(c), the distance to the temperature below which the risk of increased coking due to condensation increases is the lowest. Therefore, Example 4(b) has the highest safety against coking due to condensation and can be selected when this is the primary target.

[0172] Regarding the pressure drop in the inner passage of the effluent, which affects decomposition selectivity, Example 4(a) showed the lowest pressure drop, followed by Example 4(c), and then Example 4(b) showed a significantly higher pressure drop. The high effluent pressure drop in Example 4(b) is due to the significantly longer passage length compared to Examples 4(a) and 4(c).

[0173] TIFF2026516193000006.tif105170Table E

[0174] With regard to residence time and cooling rate, referring to the cooling of the effluent up to a temperature of 650°C, the best values ​​were observed with the configuration of Example 4(b). This is due to the maximum temperature difference at the effluent inlet between the effluent and the raw material. However, considering the equally high heat transfer surface area required in Example 4(b) and the high passage metal temperature observed in Example 4(a), the configuration specified in Example 4(c) may be considered the best solution in the application cases shown herein when the heat transfer surface area is limited.

[0175] In general, those skilled in the art will select from the configurations of Examples 4(a) to 4(c) depending on the requirements given by specific technical and economic boundary conditions.

[0176] While several exemplary embodiments of this disclosure have been described, it should be apparent to those skilled in the art that these are merely illustrative examples, not limitations. Numerous modifications and other embodiments are within the scope of those skilled in the art and are considered to be within the scope of this disclosure. In particular, many of the embodiments presented herein involve specific combinations of method actions or system elements, but it should be understood that these actions and these elements may be combined in other ways to achieve the same objective. Those skilled in the art should understand that the parameters and configurations described herein are illustrative, and that actual parameters and / or configurations will depend on the specific application using the systems and techniques of this disclosure. Those skilled in the art should also be able to recognize or verify equivalents to specific embodiments of this disclosure using routine experiments. Therefore, it should be understood that the embodiments described herein are presented merely as examples, and embodiments of this disclosure may be implemented in ways other than those specifically described, within the scope of any appended claims and their equivalents.

[0177] Furthermore, the scope of this disclosure shall be interpreted to include, and shall be deemed to be within the scope of, various modifications, combinations, additions, alterations, etc., to the embodiments described above and therein. Accordingly, the various features and characteristics described herein may be selectively interchangeable and applied to other exemplary and non-exemplary embodiments, and numerous variations, modifications, and additions may be made thereto without departing from the spirit and scope of this disclosure as set forth in the appended claims.

[0178] An exemplary thermal energy recovery assembly A for recovering thermal energy from high-temperature reactor effluent to heat the raw materials for a gas combustion reactor includes an inner passage having a first inlet configured to receive high-temperature reactor effluent from a gas combustion reactor, and an outer passage disposed around the inner passage, with one outer passage surrounding the inner passage. The outer passage may have a second inlet configured to receive the raw materials for the gas combustion reactor, and the outer passage may be configured to use the raw materials for the gas combustion reactor as a cooling medium and recover thermal energy from the high-temperature reactor effluent before supplying the raw materials to the gas combustion reactor. The outer passage may be configured to enhance heat transfer from the high-temperature reactor effluent to the raw materials within the outer passage.

[0179] In some embodiments, high-temperature reactor effluent may reach a first inlet via a gas inlet chamber or other connector. In some embodiments, cooling may be supplied to the gas inlet chamber or other connector. In some embodiments, the gas chamber may connect one or more decomposition coils to one or more internal passages. In some embodiments, a header may be provided to connect two or more external passages to feedstock. In some embodiments, cooled and decomposed gases from two or more internal passages may be collected using the header. In some embodiments, heated feedstocks from two or more external passages may be combined via the header. In some embodiments, multiple rings may be included within a single mechanical device capable of receiving high-temperature effluents from multiple decomposition coils via a gas inlet chamber or other connector and receiving low-temperature feedstocks from a feedstock header.

[0180] In the exemplary assembly A described above, the outer passage includes at least one heat transfer enhancing section that enhances heat transfer from the inner passage to the outer passage.

[0181] In the exemplary assembly A described above, the outer passage includes a first stage, and at least one heat transfer enhancing section comprises one or more plate impact sections, piccolo impact sections, turbulence enhancing sections, or surface area increasing sections.

[0182] In exemplary assembly A, the heat transfer enhancement portion due to collision may refer to a fluid flow passing through the outer passage, and the average direction of the fluid flow as it moves from the inlet to the outlet may be substantially parallel to the inner passage, for example, intentionally guided toward the inner passage using a geometry feature introduced into the outer passage. In some embodiments, this guided (collision) flow may be perpendicular to the inner passage, or directed toward the inner passage at an angle greater than 30 degrees with respect to the axis of the inner passage, while the velocity of the guided flow may be relatively greater than the surface velocity of the outer passage flow (e.g., the volumetric flow rate of the outer passage flow divided by the annular cross-sectional region between the inner and outer passages). In some embodiments, the geometry feature that facilitates collision may include, for example, a nozzle and / or opening directed toward the inner passage, and / or an obstacle placed in a channel that can redirect the fluid toward the inner passage from a more parallel direction, directly toward the outer surface of the inner passage. These exemplary features may be implemented in a periodic manner, resulting in collision zones occurring at multiple intervals along the length and / or circumference of the inner passage, for example. The applicant has found that introducing such impact features can increase the heat transfer coefficient compared to the heat transfer coefficient obtained by parallel flow through the outer passage. Furthermore, the applicant has found that, with respect to an appropriate level of heat transfer enhancement, the ratio of the impact flow velocity to the surface velocity can be greater than 2, greater than 5, or greater than 10. The velocity of the impact flow can be approximated as a volumetric flow rate divided by the total flow area defined by the nozzle or opening through which the flow is guided, in the case of a nozzle or opening. Furthermore, it has been found that the heat transfer enhancement is more suitable at a certain distance between the impact guidance feature (e.g., nozzle or opening 54) and the inner passage, where this distance is from approximately equal to the diameter of the nozzle or opening 54 to about 12 times the diameter, or from approximately equal to the diameter to about 10 times the diameter, or from about 2 times the diameter to about 8 times the diameter. Examples of impact features may include plate impact features and / or piccolo impact features.

[0183] In the exemplary assembly A described above, the outer passage includes a plate impact section disposed between the upstream and downstream ends. The plate impact section may include a first flow path having a stepped inlet upstream and closed to the flow at the downstream end. The plate impact section may also include a second flow path having a stepped outlet at the downstream end. The second flow path may be disposed between the first flow path and the inner passage. The plate impact section may further include a wall separating the first flow path from the second flow path. The wall may define an opening that fluidly connects the first and second flow paths. The plate impact section may be configured to receive raw material through the stepped inlet, allow the raw material to flow from the first flow path through the opening in the wall to the second flow path, cause it to impact the outer surface of the inner passage, and discharge the raw material through the stepped outlet of the second flow path.

[0184] In the exemplary assembly A described above, the outer passage includes a piccolo impact section. The piccolo impact section may include an upstream divider disposed around and within the inner passage, and a downstream divider disposed within the outer passage, downstream of the upstream divider, and also disposed around and within the inner passage. The downstream divider may define at least one stage outlet. The piccolo impact section may further include a chamber defined within and around the inner passage between the upstream and downstream dividers, and a piccolo passage, the piccolo passage being parallel to the inner passage, at an angle to the inner passage, and / or straight from the inner passage, curved, bent, and / or offset. The piccolo passage may extend from the upstream divider through the chamber to the downstream divider. The piccolo passage may include a stage inlet for receiving incoming material and a plurality of openings defined within the piccolo passage, the openings may be oriented toward the outer surface of the inner passage. The piccolo impact section may be configured to receive the raw material from a step inlet, to flow the raw material from the piccolo passage through multiple openings into the chamber, to cause the flow to impact the outer surface of the inner passage, and / or to discharge the raw material from the chamber through at least one step outlet.

[0185] In the above exemplary assembly A, at least one stage includes a first stage and a second stage, and is one or more of the following: (1) The inner passage of the first stage has a first outlet and is configured to allow high-temperature reactor effluent to flow from a first inlet to a first outlet, and the outer passage of the first stage has a second outlet and is configured to allow raw materials to flow from a second inlet to a second outlet, the second inlet of the first stage is adjacent to the first outlet of the first stage, and the second outlet of the first stage is adjacent to the first inlet of the first stage, (2) The second stage includes a plate impact section, a piccolo impact section, a turbulence enhancement section, or includes at least one heat transfer enhancement section which includes one or more surface area increasing sections, and the second stage is in series with the first stage, or (3) the second stage includes an inner passage having a first inlet and a first outlet, configured to carry reactor effluent from the first inlet to the first outlet of the second stage, and the outer passage having a second inlet and a second outlet is configured to carry raw materials from the second inlet to the second outlet of the second stage, the second inlet of the second stage being adjacent to the first outlet of the second stage, and the second outlet of the second stage being adjacent to the first inlet of the second stage.

[0186] In the exemplary assembly A described above, at least one heat transfer reinforcement portion of the first stage includes a first impact hole having a first diameter, and at least one heat transfer reinforcement portion of the second stage includes a second impact hole having a second diameter, the second diameter being different from the first diameter.

[0187] In the above exemplary assembly A, the internal passage includes a heat transfer enhancement section.

[0188] In the above exemplary assembly A, the inner passage has a first outlet and is configured to carry high-temperature reactor effluent from a first inlet to a first outlet, and the outer passage has a second outlet and is configured to carry raw materials from a second inlet to a second outlet, which is one of the following: the second inlet is adjacent to the first outlet and the second outlet is adjacent to the first inlet, or the first inlet is adjacent to the second inlet and the first outlet is adjacent to the second outlet.

[0189] In the exemplary assembly A described above, the thermal energy recovery assembly includes a plurality of parallel inner passages, each inner passage located within an outer passage, and each outer passage has at least one or more plate impact sections, piccolo impact sections, or turbulence enhancing sections, thereby enhancing heat transfer from the inner passages to the outer passages as defined within the outer passage. In some embodiments, the thermal energy recovery assembly may include a plurality of parallel inner passages, each inner passage located within an outer passage, and the outer passage and optionally the inner passages have one or more heat transfer enhancing sections, thereby enhancing heat transfer from the inner passages to the outer passages as defined within the outer passage.

[0190] In the exemplary assembly A described above, the thermal energy recovery assembly is configured to cool the high-temperature reactor effluent at a rate of, for example, at least 2.5 Kelvin / ms, at least 3.5 Kelvin / ms, at least 4.5 Kelvin / ms, at least 5 Kelvin / ms, or at least 5.5 Kelvin / ms, and the cooling rate may be defined as the inlet temperature (in K degrees) of the high-temperature reactor effluent minus 923 K and divided by the residence time required to cool the high-temperature reactor effluent from its temperature to 923 K. The above applies except when the inlet temperature (in K degrees) of the high-temperature reactor effluent is less than 923 K, or when the temperature of the cooled reactor effluent is greater than 923 K. In this case, the cooling rate may be defined as the inlet temperature (in K degrees) of the high-temperature reactor effluent minus the temperature of the cooled reactor effluent when it leaves the thermal energy recovery assembly and divided by the residence time of the effluent in the assembly. In some embodiments, the thermal energy recovery assembly may be configured such that the pressure drop of the high-temperature reactor effluent passing through the thermal energy recovery assembly is less than 0.35 bar, less than 0.30 bar, less than 0.25 bar, or less than 0.20 bar. The residence time of the high-temperature reactor effluent within the thermal energy recovery assembly is less than 100 milliseconds, less than 95 milliseconds, less than 90 milliseconds, less than 85 milliseconds, less than 83 milliseconds, or less than 80 milliseconds, or the pressure drop of the raw material passing through the thermal energy recovery assembly is less than 15 bar, less than 12 bar, less than 10 bar, less than 8 bar, or less than 6 bar.

[0191] In the exemplary assembly A described above, the thermal energy recovery assembly is configured to preheat the raw material to at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least 450°C, at least 475°C, at least 500°C, at least 525°C, at least 550°C, at least 575°C, at least 600°C, at least 625°C, or at least 650°C.

[0192] In the above example assembly A, the high-temperature reactor effluent enters the thermal energy recovery assembly at temperatures exceeding 575°C, 600°C, 610°C, 620°C, 630°C, 640°C, or 650°C.

[0193] In the exemplary assembly A described above, the oxidizer for the combustion decomposition furnace is preheated in one or more stages to temperatures above 180°C, above 200°C, above 250°C, and above 280°C by using the thermal energy obtained from the rapid cooling of the decomposition gas in the form of rising steam or boiler feedwater.

[0194] In the exemplary assembly A described above, the oxidizer for the combustion decomposition furnace is preheated in one or more stages to temperatures above 400°C, above 550°C, above 600°C, above 700°C, and above 780°C relative to the flue gas from the combustion of the fuel gas with the oxidizer.

[0195] In the above example assembly A, the oxidizer is preheated in multiple stages to temperatures exceeding 400°C, 550°C, 600°C, 700°C, and 780°C by a combination of the methods described above.

[0196] In the above example assembly A, the oxidizer, preheated to temperatures exceeding 400°C, 550°C, 600°C, 700°C, and 780°C, is combusted with hydrogen or hydrogen-enriched steam in the radiating zone of the combustion decomposition furnace, supplying heat to the reaction zone.

[0197] A furnace assembly for heating raw materials to provide high-temperature reactor effluent may include the exemplary thermal energy recovery assembly A and a high-efficiency low-emission combustion cracking furnace, the high-efficiency low-emission combustion cracking furnace including a reaction area configured to heat the raw materials to the decomposition temperature of one or more of the following: ethane, propane, butane, condensates, light naphtha, heavy naphtha, diesel fuel, pyrolysis oil, materials derived from processing and refining flows, Fischer-Tropsch products, plastic waste, or biological raw materials.

[0198] Method B for producing olefins includes supplying reaction materials to an outer passage of a thermal energy recovery assembly, heating the reaction materials in the outer passage of the thermal energy recovery assembly, and outputting the preheated reaction materials. Exemplary Method B may further include supplying the preheated reaction materials to a high-efficiency, low-emission combustion cracking furnace having a reaction area for heating the preheated reaction materials, cracking the preheated reaction materials in the reaction area, and outputting a high-temperature reactor effluent containing the cracked hydrocarbons and olefins. Exemplary Method B may further include supplying the high-temperature reactor effluent to an inner passage of a thermal energy recovery assembly, and supplying further reaction materials to an outer passage of the thermal energy recovery assembly. Exemplary Method B may also include heating further reaction materials by transferring heat from the high-temperature reactor effluent to the further reaction materials via the thermal energy recovery assembly.

[0199] In the exemplary method B described above, one or more of the following are performed: (1) supplying high-temperature reactor effluent to an inner passage of a thermal energy recovery assembly, which includes quenching the high-temperature reactor effluent via heat transfer to further reaction materials, for example, as described herein; or (2) heating reaction materials in an outer passage of a thermal energy recovery assembly, which includes preheating the reaction materials via heat transfer from the high-temperature reactor effluent to the reaction materials. The exemplary method B described above further includes enhancing heat transfer to further reaction materials by providing a heat transfer enhancing section on one or more of the outer or inner passages, the heat transfer enhancing section including one or more plate impact sections, piccolo impact sections, or turbulence enhancing sections.

[0200] In the exemplary method B described above, supplying the high-temperature reactor effluent to the internal passage of the thermal energy recovery assembly includes supplying the high-temperature reactor effluent to the internal passage of the thermal energy recovery assembly at a temperature of at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least 450°C, at least 475°C, at least 500°C, at least 525°C, at least 550°C, at least 575°C, at least 600°C, at least 625°C, and at least 650°C.

[0201] In the exemplary method B described above, heating the reaction material in the outer passage of the thermal energy recovery assembly using the high-temperature reactor effluent, and outputting the preheated material, includes heating the reaction material to a temperature of at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least 450°C, at least 475°C, at least 500°C, at least 525°C, at least 550°C, at least 575°C, at least 600°C, at least 625°C, or at least 650°C.

Claims

1. A method for producing an olefin, the method comprising preheating a reaction material, igniting a conversion reactor, subjecting the reaction material to conversion in the conversion reactor, drawing a product gas from the conversion reactor, and cooling the product gas drawn from the conversion reactor. - The preheating and cooling include transferring heat from the product gas or a portion of the product gas to the reaction material or a portion of the reaction material using a thermal energy recovery assembly, the thermal energy recovery assembly comprising one or more inner passages and one or more outer passages coaxially surrounding the inner passage(s), - The thermal energy recovery assembly includes one or more heat transfer reinforcing structures that enhance heat transfer from the inner passage(s) to the outer passage(s), - The preheating and cooling further include passing the reaction raw material or a portion of the reaction raw material through the outer passage(s) of the thermal energy recovery assembly and passing the product gas or a portion of the product gas through the inner passage(s) of the thermal energy recovery assembly. - Ignition of the reactor includes supplying an oxidizer gas at an oxidizer gas temperature level exceeding 400°C using an oxidizer gas preheating system, and burning a fuel gas containing hydrogen and / or one or more hydrocarbons using the oxidizer gas at the said temperature level. - A method wherein the thermal energy recovery assembly is configured to satisfy a set of operating constraints, the set of operating constraints includes a first temperature constraint relating to the outside temperature of the sealed portion of the inner passage of the thermal energy recovery assembly, and a second temperature constraint relating to the inside temperature of the sealed portion of the inner passage of the thermal energy recovery assembly, wherein the first temperature constraint limits the outside temperature to a first temperature range, and the second temperature constraint limits the inside temperature to a second temperature range.

2. The method according to claim 1, wherein the first temperature range is between 550 and 750°C, and / or the second temperature range is between 150 and 350°C.

3. The thermal energy recovery assembly comprises one heat recovery stage, or several heat recovery stages arranged in parallel or in series, each of the several heat recovery stages provided in either a counterflow or parallel flow configuration, wherein in the counterflow configuration, the product gas or a portion of the product gas and the reaction material or a portion of the reaction material are passed through the heat recovery stage in opposite directions, and in the parallel flow configuration, the product gas or a portion of the product gas and the reaction material or a portion of the reaction material are passed through the heat recovery stage in the same direction, according to claim 1 or 2.

4. The method according to claim 3, wherein the product gas or a portion of the product gas is passed through one of the heat recovery stages, which are provided in a parallel flow configuration, before being further cooled.

5. The method according to claim 4, wherein the further cooling is carried out using different heat recovery stages of the heat recovery stage provided in the counterflow configuration.

6. The method according to claim 4, wherein the further cooling is carried out using a further thermal energy recovery assembly, the further thermal energy recovery assembly comprising or provided as at least one of a tube-in-tube heat exchanger and a shell-and-tube heat exchanger, and in particular provided in a counterflow configuration.

7. The method according to any one of claims 1 to 6, wherein the heat transfer reinforcing structure(s)(optional) is provided as at least one of a collision structure, a turbulence promoting structure, a high shear induction structure, and a surface area increasing structure, or includes at least one of the above.

8. The method according to claim 7, wherein the heat transfer reinforcing structure(s)(s)(s)(s) are the outer passage(s)(s)(s) of the thermal energy recovery assembly or are provided within the outer passage(s)(s), and / or are at least one heat recovery stage of the thermal energy recovery assembly or are provided within the at least one heat recovery stage.

9. The method according to any one of claims 1 to 8, wherein the preheating of the oxidizer includes a first indirect heating step of the mixture of the product or a portion of the mixture of the product by using an intermediate heat transfer medium.

10. A thermal energy recovery assembly configured for use in a method for producing an olefin according to any one of claims 1 to 9, the thermal energy recovery assembly comprising preheating a reaction material, igniting a conversion reactor, subjecting the reaction material to conversion within the conversion reactor, extracting a product gas from the conversion reactor, and cooling the product gas extracted from the conversion reactor.

11. An apparatus for producing an olefin, comprising a thermal energy recovery assembly according to claim 10, wherein the apparatus is adapted to preheat a reaction material, ignite a conversion reactor, convert the reaction material in the conversion reactor, extract a product gas from the conversion reactor, and cool the product gas extracted from the conversion reactor, and the apparatus is configured to perform at least part of the preheating and cooling by transferring heat from the product gas or a portion of the product gas to the reaction material or a portion of the reaction material using the thermal energy recovery assembly.

12. The apparatus according to claim 11, wherein the thermal energy recovery assembly comprises one or more inner passages and one or more outer passages coaxially surrounding the inner passages (or more), and the apparatus is configured to perform preheating and cooling by passing the reaction material or a portion of the reaction material through the outer passages (or more) of the thermal energy recovery assembly and passing the reaction material or a portion of the reaction material through the inner passages (or more) of the thermal energy recovery assembly.

13. The apparatus according to claim 11 or 12, further configured to ignite the reactor, including supplying an oxidizer gas at an oxidizer gas temperature level exceeding 400°C using an oxidizer gas preheating system, and burning a hydrogen-containing fuel gas at a fuel gas temperature level using the oxidizer gas.

Images