Systems and methods for upgrading hydrocarbon-containing feeds

Abstract

A reactor system for upgrading a hydrocarbon-containing feed may comprise a channel for receiving the hydrocarbon-containing feed; a first electrical conductor configured to transfer heat to the channel; a second electrical conductor adjacent to the first electrical conductor, the second electrical conductor configured to transfer heat to the channel and electrically connected to the first electrical conductor; a third electrical conductor adjacent to the second electrical conductor, the third electrical conductor configured to transfer heat to the channel and electrically connected to at least one of the first electrical conductor and the second electrical conductor, wherein the first through third electrical conductors are not in direct contact with the channel, the first and third electrical conductors have a greater resistivity than the second conductor, a resistivity ratio between the first and third electrical conductors and the second electrical conductor is from 8: 1 to 200:1.

Description

SYSTEMS AND METHODS FOR UPGRADING HYDROCARBON-CONTAININGFEEDSTECHNICAL FIELD

[0001] Embodiments of the present disclosure generally relate to systems and processes for upgrading hydrocarbons.BACKGROUND

[0002] Ethylene is widely used as an intermediate in the petrochemical industry and its production exceeds that of any other intermediate organic. Much of ethylene production goes to the manufacture of ethylene oxide, ethylene dichloride and polyethylene, which are precursors to a multitude of everyday consumer products. Despite various improvements over the years in process design, reliability and safety, steam cracking furnaces used to form hydrocarbons such as ethylene remain heavily reliant on a narrow range of combustible fossil fuels to provide process heat and energy, leading to substantial greenhouse gas emissions, including to pre-heat feed composition being processed in the steam cracker. However, steam cracking process to produce ethylene requires roughly half the energy required of competing processes (e.g., direct Ci conversion technologies) and are projected to remain as the most energy efficient process.

[0003] The growth and availability of renewable electricity creates an opportunity to use renewable energy in the formation of ethylene, eliminating the need to burn fossil fuels, and achieve a lower emission process. Various electric heating technologies such as impedance, induction, plasma, and microwaves may be used in place of combustion fired heating to generate and effectively transfer heat into the radiant channels of steam cracking furnaces. However, there is still need for systems that can form ethylene and other hydrocarbons via heating with renewable electricity.SUMMARY

[0004] Moreover, electrification of the cracking process, unlike conventional gas fired furnace, gives an opportunity better design the application and control of heat so to maximize the yield and minimize the energy consumption.

[0005] Particularly, in the application of direct electrical heating to large scale steam cracking processes, one key challenge is how to strategically apply electrical heating to optimize the selectivity towards desired products (and avoid overcracking) while also not consuming excess electricity. For instance, when operating a reactor under continuous heating at temperatures just over the required of heat enthalpy for a reaction, the yields commonly move towards equilibrium conditions. Further, in these operating conditions, thermal inertia and poor heat transfer can also negatively impact the conversion rate. Accordingly, increased temperatures may be used to increase the conversion rate and hopefully the desired yields under Arrhenius’s law. Unfortunately, increased temperatures in a continuous heating operation can also subject the feed to overcracking, resulting in the formation of undesired byproducts such as naphthalene and coke. These byproducts in turn reduce the desired yield along with a host of other negative effects, while the increased temperature raises the energy demand for the reactor.

[0006] Accordingly, methods are desired that improve electricity consumption, improve selectivity towards desired products, and minimize overcracking. One such option is to modulate the heating profile across the reactor. In theory, by modulating the heating profile across the reactor to include heating and cooling sections, the hydrocarbon feed may be subjected to a series of discrete heating and quenching process that supply the needed reaction severity to produce the desired reaction pathways while also not continuously subjecting the feed to excess heat that results in overcracking.

[0007] Dong et ah, provides a method of cracking in which micro or nanopulses of electrical power are provided to discrete areas of a reactor channel, thereby creating instances of great temperature deviation from hot to cold, resulting in improved energy efficiency and yield. Nature 605 Dong et al., Programmable heating and quenching for efficient thermochemical synthesis, pages 470-476 (2022). However, without being limited by theory, such temperature variations as in Dong et al. may also render the reactor channel susceptible to rapid temperature aging, potentially risking integrity to the channel over an extended period of time. Accordingly, methods are desired that modulate the heating profile while not exposing the reactor channels to increased temperature-induced wear.

[0008] Accordingly, embodiments herein accomplish the aforementioned goals by providing a modulated heating profile through one or more electrical conductors of alternating highresistivity and low resistivity in proximity to a reactor channel. When supplied with a constant electrical current, this arrangement of conductors alternatively heats / upgrades the hydrocarbon- containing stream on the high resistivity segments and cools / quenches (by heating to a lesser degree) the hydrocarbon-containing stream on the low resistivity segments. The resulting arrangement increases the desired yield of products and reduces the needed energy consumption as compared to a constant heating / resistivity profile. The resulting arrangement also exposes discrete areas of the channel to a consistent temperature, reducing the degree of temperature- induced aging of the channel material.

[0009] Embodiments of this disclosure may comprise a reactor system for upgrading a hydrocarbon-containing feed. The reactor system may comprise a channel comprising an inlet and an outlet, the least one channel configured to receive the hydrocarbon-containing feed; a first electrical conductor configured to transfer heat to the channel; a second electrical conductor adjacent to the first electrical conductor, the second electrical conductor configured to transfer heat to the channel and electrically connected to the first electrical conductor; a third electrical conductor adjacent to the second electrical conductor, the third electrical conductor configured to transfer heat to the channel and electrically connected to at least one of the first electrical conductor and the second electrical conductor. In the reactor system, the first through third electrical conductors are not in direct contact with the channel, the first and third electrical conductors have a greater resistivity than the second conductor, a resistivity ratio between the first electrical conductor and second electrical conductor is from 8:1 to 200:1 , and a resistivity ratio between the third electrical conductor and second electrical conductor is from 8:1 to 200:1.

[0010] Additional embodiments of this disclosure may comprise a process of upgrading a hydrocarbon-containing feed utilizing a reactor system, the process comprising: introducing the hydrocarbon-containing feed into a channel of the reactor system, the reactor system also comprising a first conductor, a second conductor, and a third conductor, wherein the first through third conductors are configured to transfer heat to the channel, the first electrical conductor is electrically connected to the first electrical conductor, the third electrical conductor is electrically connected to at least one of the first electrical conductor and the second electrical conductor; a resistivity ratio between the first electrical conductor and second electrical conductor is from 8: 1 to 200: 1 , and a resistivity ratio between the third electrical conductor and second electrical conductor is from 8: 1 to 200: 1 ; applying electrical current to the first, second, and thirdconductors, wherein the first and third conductors have a greater resistance than the second conductor; and alternatively heating the hydrocarbon-containing feed with greater and lesser degrees of heat along a length of the channel to form an effluent stream.

[0011] Yet other embodiments of this disclosure may comprise a reactor system for upgrading a hydrocarbon-containing feed. The reactor system may comprise a channel comprising an inlet and an outlet, the channel configured to receive the hydrocarbon-containing feed; a first electrical conductor configured to transfer heat to the channel; a second electrical conductor adjacent to the first electrical conductor, the second electrical conductor configured to transfer heat to the channel and electrically connected to the first electrical conductor; and a third electrical conductor adjacent to the second electrical conductor, the third electrical conductor configured to transfer heat to the channel and electrically connected to at least one of the first electrical conductor and the second electrical conductor. In the reactor system, the first and third electrical conductors have a greater heat flux than the second conductor, a heat flux ratio between the first and second conductors is from 3: 1 to 140:1, and a heat flux ratio between the third and second conductors is from 3: 1 to 140:1.BRIEF DESCRIPTION OF FIGURES

[0012] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, in which:

[0013] FIG. 1 is a schematic view of a reactor system, according to embodiments herein;

[0014] FIG. 2 is a is an illustration of a reactor system, according to embodiments herein;

[0015] FIG. 3 is a graphical illustration of the temperature profile for the hydrocarbon- containing stream and the channel surface for a reactor system, according to embodiments herein;

[0016] FIG. 4 is a graphical illustration of the temperature profile for the hydrocarbon- containing stream and the channel surface for another reactor system, according to embodiments herein;

[0017] FIG. 5 is a graphical illustration of the temperature profile for the hydrocarbon- containing stream and the channel surface for yet another reactor system, according to embodiments herein; and

[0018] FIG. 6 is a graphical illustration of the temperature profile for the hydrocarbon- containing stream and the channel surface for yet another reactor system, according to embodiments herein.DETAILED DESCRIPTION

[0019] Embodiments of the present disclosure generally relate to systems and processes for upgrading hydrocarbons.

[0020] It should be understood that the process for upgrading hydrocarbons of this disclosure may be embodied in different forms and should not be construed as limited to the specific embodiments set forth in this disclosure. Rather, embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the subject matter to those skilled in the art. Specific embodiments will now be described with references to the figures.

[0021] FIGS. 1 and 2 illustrate reactor systems 100 for upgrading a hydrocarbon-containing feed, according to embodiments described herein. As shown in FIGS. 1 and 2, the reactor system 100 may comprise a channel 102, a first electrical conductor 111 , a second electrical conductor 112, and a third electrical conductor 113. As shown in FIG. 2, the reactor system 100 may additionally comprise a fourth electrical conductor 114 and a fifth electrical conductor 115. Furthermore, the reactor system 100 may additionally comprise a sixth electrical conductor, a seventh electrical conductor, an eighth electrical conductor, or any number of additional electrical conductors (not shown). In other words, the reactor system 100 according to embodiments may comprise any number of electrical conductors greater than three electrical conductors, which may be referred to collectively herein as “the one or more conductors”. As described hereinbelow, each of the one or more conductors may be configured to transfer heat to the channel 102, and thereby transfer heat to the hydrocarbon-containing feed, when the one or more conductors are supplied with electric current. However, some of the one or more conductors will supply lesser amounts of heat than others of the one or more conductors, such that some of the one or more conductors may effectively cool the hydrocarbon-containing feed due to process chemistry endothermicity.

[0022] Still referring to FIGS. 1 and 2, the channel 102 may comprise an inlet 103 for receiving the hydrocarbon-containing feed and an outlet 104 for releasing an effluent stream from the channel 102. In embodiments, the channel 102 may have a curve along the length of thechannel 102. The shape of the channel 102 can vary to resemble, for example, the letter M, W, U, inverted U, I, or combinations thereof (not shown). The reactor system 100 may additionally comprise an electrical insulation material 105 positioned along an exterior of the channel 102, wherein the one or more conductors are positioned along an exterior of the electrical insulation material 105. In embodiments, the electrical insulation material 105 may be any material known to not be electrically conductive but that are thermally conductive, including but not limited to ceramic thereof. Further, the electrical insulation material 105 may be air, such that the one or more conductors are placed proximate to, but not in direct contact with, the channel 102.

[0023] As previously stated, the one or more conductors may be configured to transfer heat to the channel 102 when supplied with electric current. As such, the one or more conductors may be supplied with electric current using an electrical power source 106, such as via one or more electrical lead lines 107. The reactor system 100 may also further comprise a vessel 120 defined by a first end 121, a second end 122, and at least one side wall 123 extending from the first end 121 to the second end 122. In embodiments including the vessel 120, the channel 102 may be positioned between the first end 121 and the second end 122 of the vessel 120. In other words, the inlet 103 end and the outlet 104 end may be positioned proximal to the first and second ends 121 / 122 respectively, although this is not required.

[0024] Still referring to FIGS. 1 and 2, the second electrical conductor 112 may be adjacent to the first electrical conductor 11 1. The second electrical conductor 112 may also be electrically connected to the first electrical conductor 111. Likewise, the third electrical conductor 1 13 may be adjacent the second electrical conductor 112 and may be electrically connected to at least one of the first electrical conductor 1 11 and the second electrical conductor 112. Similarly, the fourth electrical conductor 114 may be adjacent the third electrical conductor 113 and may be electrically connected to at least one of the first through third electrical conductors. Similarly, the fifth electrical conductor 1 15 may be adjacent the fourth electrical conductor 114 and may be electrically connected to at least one of the first through fourth electrical conductors. Similarly, the sixth electrical conductor may be adjacent the fifth electrical conductor 1 15 and may be electrically connected to at least one of the first through fifth electrical conductors. Similarly, the seventh electrical conductor may be adjacent the sixth electrical conductor and may be electrically connected to at least one of the first through sixth electrical conductors. Similarly, the eighth electrical conductor may be adjacent the seventh electrical conductor and may be electricallyconnected to at least one of the first through seventh electrical conductors. Finally, the one or more additional electrical conductors may be adjacent the eighth electrical conductor and may be electrically connected to at least one of first through eighth electrical conductors. As used herein, “electrically connected” may mean that two components are in direct contact with each other or indirectly coupled using an intermediary means.

[0025] Still referring to FIGS. 1 and 2, and as previously stated, embodiments herein may be directed to forming a modulated heating profile across the reactor which may be effected through the one or more electrical conductors having alternating resistivity, such as alternating high resistivity and low resistivity. For example, and in embodiments, the first, third, fifth, and seventh electrical conductors (collectively referred to herein as the “high resistivity conductors”) may have a greater resistivity than the second, fourth, sixth, and eighth electrical conductors (collectively referred to herein as the “low resistivity conductors”). Similarly, the second, fourth, sixth and eighth electrical conductors may have a lesser resistivity than the first, third, fifth, and seventh electrical conductors. For example, and in embodiments, a resistivity ratio between the high resistivity conductors and the low resistivity conductors may be from 8:1 to 200:1 , such as from 8: 1 to 10: 1 , from 10: 1 to 20:1 , from 20:1 to 50:1 , from 50: 1 to 100: 1 , from 100: 1 to 150: 1, from 150:1 to 200:1 , or combinations of the previous ranges or smaller ranges therein. It should be understood that the resistivity ratio between individual, adjacent conductors may vary within the above ranges, such that, for example, a resistivity ratio between the first electrical conductor and the second electrical conductor is different than the resistivity ratio between the third electrical conductor and the second electrical conductor. Moreover, the one or more additional electrical conductors may have resistivity values or ratios similar or identical to the high resistivity conductors, the low resistivity conductors, or combinations thereof, depending on where the one or more additional electrical conductors are located in the sequence.

[0026] Similarly, the high resistivity conductors may have an average heat flux that is greater than the average heat flux of the low resistivity conductors. For example, and in embodiments, a heat flux ratio between the high resistivity conductors and the low resistivity conductors may be from 3: 1 to 200: 1 , such as from 3:1 to 5:1, from 5:1 to 10:1, from 10: 1 to 40: 1 , from 40:1 to 70:1, from 70: 1 to 100:1 , from 100:1 to 130:1, from 130:1 to 140: 1 , or any combination of the previous ranges or smaller range therein.

[0027] In embodiments, the high resistivity conductors may have an electric resistivity of from greater than 10 gQ m (micro-ohm-meters), such as from 10 to 20 gQ m, from 20 to 40 gfl m, from 40 to 60 gQ m, from 60 to 80 g£Lm, from 80 to 100 gQ m, from 100 to 125 gQ m, from 125 to 150 gQ-m, from 150 to 175 gQ-m, from 175 to 200 gQ m, or combinations of the previous ranges or smaller ranges therein. In embodiments, the electric resistivity of the one or more electrical conductors may vary over the length of the one or more electrical conductors, or among each of the individual conductors of the high resistivity conductors.

[0028] In embodiments, the low resistivity conductors may have an electric resistivity of less than 2 gQ m (micro-ohm-meters), such as from 0.1 to 0.2 gQ m, from 0.2 to 0.4 gQ m, from 0.4 to 0.6 gQ m, from 0.6 to 0.8 gQ-m, from 0.8 to 1 gQ m, from 1 to 1.1 gQ m, from 1.1 to 1.25 gQ m, from 1.25 to 1.5 gQ-m, from 1.5 to 1.75 gQ-m, from 1.75 to 2 gQ m, or combinations of the previous ranges or smaller ranges therein. In embodiments, the electric resistivity of the one or more electrical conductors may vary over the length of the one or more electrical conductors, or among each of the individual electrical conductors of the low resistivity conductors.

[0029] Similarly, in embodiments, the high resistivity conductors may have an average heat flux of greater than 70 kW / m2, such as from 70 kW / m2to 80 kW / m2, from 80 to 90 kW / m2, from 90 to 100 kW / m2, from 100 to 110 kW / m2, from 1 10 to 120 kW / m2, from 120 to 130 kW / m2, from 130 to 140 kW / m2, or combinations of the previous ranges or smaller ranges therein. In embodiments, the heat flux of the one or more electrical conductors may vary over the length of the one or more electrical conductors, or among each of the individual conductors of the high resistivity conductors.

[0030] Likewise, in embodiments, the low resistivity conductors may have an average heat flux of less than 20 kW / m2, such as from 1 kW / m2to 2 kW / m2, from 2 to 4 kW / m2, from 4 to 8 kW / m2, from 8 to 12 kW / m2, from 12 to 16 kW / m2, from 16 to 18 kW / m2, from 18 to 20 kW / m2, or combinations of the previous ranges or smaller ranges therein. In embodiments, the heat flux of the one or more electrical conductors may vary over the length of the one or more electrical conductors, or among each of the individual conductors of the low resistivity conductors.

[0031] In embodiments, the one or more electrical conductors described herein may have an average thickness of from 0.01 meters to 0.1 meters, such as from 0.01 to 0.02 meters, from 0.02 to 0.03 meters, from 0.03 to 0.04 meters, from 0.04 to 0.06 meters, from 0.06 to 0.08 meters, from 0.08 meters to 0.09 meters, from 0.09 meters to 0.1 meters, or combinations of the previous rangesor smaller ranges therein. Without being limited by theory, the average thickness of the one or more electrical conductors may in turn impact the resistivity and the average heat flux.

[0032] In embodiments, the high resistivity conductors may comprise silicon carbide, molybdenum silicide, a composite of zirconium diboride and silicon carbide, graphite, or combinations thereof. The low resistivity conductors may comprise graphite, a nickel-chromium alloy such as 35Ni-35Cr, or combinations thereof. The high resistivity conductors, the low resistivity conductors, or both may also further comprise micro alloys of other metals, such as aluminum.

[0033] Still referring to FIGS. 1 and 2, and as previously stated, embodiments herein may be directed to forming a modulated heating profile across the reactor which may be effected through the one or more electrical conductors having alternating qualities of high resistivity and low resistivity. Further yet, the heating profile across the reactor may be further modified by adjusting the average length of each of the high resistivity conductors, the average length of the low resistivity conductors, or both. For example, and as illustrated in the Examples herein, increasing the length of the low resistivity conductors with respect to the high resistivity conductors may result in lesser yields of by-products and increased yields of desired products, such as ethylene for a hydrocarbon-containing feed comprising ethane. Furthermore, channels that operate free of byproducts such as coke exhibit higher heat transfer rates contributing to channel 102 cooling, further limiting channel 102 overheating. Reduced coking rates also leads to longer operational runtimes, decreasing the frequency of costly reactor shutdowns needed for de-coking of the channels, and hence longer overall channel 102 lifetimes can be expected from use of longer low resistivity conductor sections.

[0034] Increasing the length of the low resistivity conductors with respect to the high resistivity conductors also may result in decreased power demand to effect the desired yields, providing further benefits. For example, and in embodiments, the reactor system 100 may comprise a length ratio between the high resistivity conductors and the low resistivity conductors of from 1 : 1 to 4: 1 , such as from 1 :1 to 1.5:1 , from 1.5:1 to 2:1 , from 2:1 to 3:1 , from 3:1 to 4:1 , or combinations of the previous ranges or smaller ranges therein.

[0035] This disclosure is also directed towards processes for upgrading hydrocarbon- containing feeds using the reactor systems 100 described herein. The processes may use any of the reactor systems 100 previously described.

[0036] A process of upgrading the hydrocarbon-containing feed may comprise introducing the hydrocarbon-containing feed into the channel 102 of the reactor system 100; applying electrical current to the first, second, and third conductors; and alternatively heating the hydrocarbon-containing feed with greater (high resistivity conductors) and lesser degrees of heat (low resistivity conductors) along a length of the channel 102 to form an effluent stream. In embodiments, the process may further comprise applying electrical current to the fourth, fifth, sixth, seventh, and eighth electrical conductors; and alternatively heating the hydrocarbon- containing feed with greater (high resistivity conductors) and lesser degrees of heat (low resistivity conductors) along the length of the channel 102 to form an effluent stream. As previously stated, the greater and lesser degrees of heat may be accomplished by the high resistivity conductors and low resistivity conductors, respectively. This may in turn be evidenced by a greater heat flux through the high resistivity conductors and a lower heat flux through the low resistivity conductors, respectively. In other words, alternatively heating the hydrocarbon-containing feed with greater and lesser degrees of heat along a length of the channel 102 to form an effluent stream may also be regarded as alternatively exposing the hydrocarbon-containing feed to a first heat flux and a second heat flux, wherein the second heat flux is less than the first heat flux.

[0037] In embodiments, the hydrocarbon-containing feed may comprise paraffins, olefins, or combinations thereof, such as, but not limited to, methane, ethane, propane, butane, pentane, hexane, or combinations thereof. The hydrocarbon-containing feed may also comprise steam or hydrogen, such as when the reactor system 100 is utilized for steam cracking or hydrocracking, respectively.

[0038] In embodiments, heating the hydrocarbon-containing feed to the greater degree of heat (i.e. the high resistivity conductor ‘heating’ zones) may be conducted at a temperature of from 600 °C to 1200 °C, such as from 600 to 700 °C, from 700 to 800 °C, from 800 to 900 °C, from 900 to 1000 °C, from 1000 to 1100 °C, from 1100 to 1200 °C, or combinations of the previous ranges or smaller ranges therein. In embodiments, heating the hydrocarbon-containing feed to the lesser degree of heat (i.e. the lower resistivity conductor ‘cooling’ zones) may be conducted at a temperature of from 600 °C to 800 °C, such as from 600 to 650 °C, from 650 to 700 °C, from 700 to 750 °C, from 750 to 800 °C, or combinations of the previous ranges or smaller ranges therein. As previously stated, the higher and lower heating temperatures, and thus the higher and lowerdegrees of heat, may be attributed to the greater heat flux through the high resistivity conductors and the lower heat flux through the low resistivity conductors, respectively.

[0039] Without being limited by theory, it should be understood that each of the heating zones attributable to each of the high resistivity conductors mentioned in embodiments herein may be at different temperatures, attributable to the resistivity of the material chosen. Likewise, it should be understood that each of the cooling zones attributable to each of the low resistivity conductors mentioned in embodiments herein may be at different temperatures, attributable to the resistivity of the material chosen.EXAMPLES

[0040] Simulations of the reactor systems herein were conducted to determine the impact of different resistivity ratios and conductor lengths had on the desired yields of the process. Visual Basic software in Excel 365 was used to model the reactor systems, utilizing a plug-flow gas phase reactor model with heat balance and pressure profile calculations. The reactor was a steam cracker containing a channel of fifty meters in length and an internal diameter of 0.1 meters. Ethane was introduced into the reactor channel at a mass flow rate of 1000 kilograms per hour (kg / h), with dilution steam mass flow at 270 kg / h for a residence time of approximately 0.5 seconds. Both ethane and the steam were introduced at approximately 650 °C and 2 bar. Ethane kinetics in the simulation was based on the Sundaram et al. (Chemical Engineering Science, 1977, Vol. 32, pages 601-608). Surface temperature of the channel was estimated based on the Nusselt number correlation presented in API (American Petroleum Institute) standard 530.

[0041] The conductors used in the simulation had a thickness of approximately 0.03 meters and were placed on either side of the channel. Four conductors (first, third, fifth, and seventh) of equivalent length having the higher resistivity and four conductors (second, fourth, sixth, and eighth) of equivalent length having the lower resistivity were alternatively positioned along the length of the channel according to embodiments herein. The insulative material used was air. In other words, the conductors did not contact the channel directly. The relative lengths of each of the segments, as well as the resistivity of the segments, was as per Table 1 below. A comparative case was also used with one conductor spanning the entire length of the channel. Assumed in the simulations was an adiabatic system with no conduction heat transfer from the high conductors to the low resistivity conductors. Without being limited by theory, while in actual practice someconduction heat transfer will occur between the high and low resistivity conductors, this can be offset by increasing the lengths of the low resistivity conductors with respect to the high resistivity conductors. In other words, while a portion of the low resistivity conductors may be subjected to and experience the greater temperatures of the high resistivity conductors, a remaining portion may experience the lowered quenching temperature, and thereby achieve the desired quenching role.

[0042] Table 1 : Simulated Reactor Properties

[0043] The results of the simulations are shown below in Table 2. Particularly, as shown in Table 2, decreasing the length ratio of high resistivity conductor segments to low resistivity conductor segments was observed to increase the yield of ethylene in the effluent stream while also reducing energy consumption. Further, increasing the resistivity ratio of high resistivity conductor segments to low resistivity conductor segments was observed to increase the yield of ethylene in the effluent stream while also reducing energy consumption.

[0044] Table 1 : Simulated Reactor Properties

[0045] It should be apparent to those skilled in the art that various modifications can be made to the described embodiments without departing from the spirit and scope of the claimed subject matter. Thus, it is intended that the specification cover modifications and variations of the described embodiments provided such modification and variations come within the scope of the appended claims and their equivalents.

[0046] The present disclosure may include one or more aspects. A first aspect of the present disclosure comprises a reactor system for upgrading a hydrocarbon-containing feed comprising: a channel comprising an inlet and an outlet, the least one channel configured to receive the hydrocarbon-containing feed; a first electrical conductor configured to transfer heat to the channel; a second electrical conductor adjacent to the first electrical conductor, the second electrical conductor configured to transfer heat to the channel and electrically connected to the first electrical conductor; a third electrical conductor adjacent to the second electrical conductor, the third electrical conductor configured to transfer heat to the channel and electrically connected to at least one of the first electrical conductor and the second electrical conductor, wherein the first through third electrical conductors are not in direct contact with the channel, the first and third electrical conductors have a greater resistivity than the second conductor, a resistivity ratio between the first electrical conductor and second electrical conductor is from 8:1 to 200:1, and a resistivity ratio between the third electrical conductor and second electrical conductor is from 8:1 to 200:1.

[0047] A second aspect may include any previous aspect and may further comprise a fourth electrical conductor adjacent to the third electrical conductor, wherein the fourth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through third electrical conductors, and has a lower resistivity than both the first and third electrical conductors; a fifth electrical conductor adjacent to the fourth electrical conductor, wherein the fifth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through fourth electrical conductors, and has a greaterresistivity than both the second and fourth conductors; a sixth electrical conductor adjacent to the fifth electrical conductor, wherein the sixth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one o f the first through fifth electrical conductors, and has a lower resistivity than the first, third, and fifth electrical conductors; a seventh electrical conductor adjacent to the sixth electrical conductor, wherein the seventh electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through sixth electrical conductors, and has a greater resistivity than the second, fourth, and sixth conductors; and an eighth electrical conductor adjacent to the seventh electrical conductor, wherein the eighth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through seventh electrical conductors, and has a lower resistivity than the first, third, fifth, and seventh electrical conductors.

[0048] A third aspect may include any previous aspect, wherein the first conductor, the third conductor, or both comprise a resistivity of greater than 10 pQ m; and the second conductor comprises a resistivity of from 1 p£2 m to 2 pQ-m.

[0049] A fourth aspect may include any previous aspect, wherein the first conductor, the third conductor, or both comprise silicon carbide, molybdenum silicide, a composite of zirconium diboride and silicon carbide, graphite, or combinations thereof; the second conductor comprises a Ni-Cr alloy; or both.

[0050] A fifth aspect may include any previous aspect, wherein the first conductor, the third conductor, or both have an average heat flux of from 70 kW / m2to 140 kW / m2; and the second conductor has an average heat flux of from 1 kW / m2to 20 kW / m2.

[0051] A sixth aspect may include any previous aspect, wherein the first conductor, the second conductor, the third conductor, or combinations thereof have an average thickness of from 0.01 meters to 0.1 meters.

[0052] A seventh aspect may include any previous aspect, and may further comprise an electrical insulation material positioned along an exterior of the channel, wherein the first, second, and third conductors are positioned along an exterior of the electrical insulation material; a vessel defined by a first end, a second end, and at least one side wall extending from the first end to the second end, the channel positioned between the first end and the second end of the vessel; anelectrical lead line configured to provide direct electrical current to the first conductor, the second conductor, the third conductor, or combinations thereof, wherein the electrical lead line is coupled to an electrical power source; or combinations thereof.

[0053] An eighth aspect may include any previous aspect, wherein a ratio of the length of the first conductor to the second conductor is from 1 :1 to 4:1 ; a ratio of the length of the third conductor to the second conductor is from 1 : 1 to 4: 1 ; or both.

[0054] A ninth aspect of the present disclosure may comprise a process of upgrading a hydrocarbon-containing feed utilizing a reactor system, the process comprising: introducing the hydrocarbon-containing feed into a channel of the reactor system, the reactor system also comprising a first conductor, a second conductor, and a third conductor, wherein the first through third conductors are configured to transfer heat to the channel, the first electrical conductor is electrically connected to the first electrical conductor, the third electrical conductor is electrically connected to at least one of the first electrical conductor and the second electrical conductor; a resistivity ratio between the first electrical conductor and second electrical conductor is from 8: 1 to 200: 1 , and a resistivity ratio between the third electrical conductor and second electrical conductor is from 8:1 to 200:1 ; applying electrical current to the first, second, and third conductors, wherein the first and third conductors have a greater resistance than the second conductor; and alternatively heating the hydrocarbon-containing feed with greater and lesser degrees of heat along a length of the channel to form an effluent stream.

[0055] A tenth aspect of the present disclosure may include the ninth aspect, and may further comprise applying electrical current to fourth, fifth, sixth, seventh, and eighth electrical conductors; and alternatively heating the hydrocarbon-containing feed with greater and lesser degrees of heat along a length of the channel to form an effluent stream, wherein the reactor system further comprises: the fourth electrical conductor adjacent to the third electrical conductor, wherein the fourth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through third electrical conductors, and has a lower resistivity than both the first and third electrical conductors, the fifth electrical conductor adjacent to the fourth electrical conductor, wherein the fifth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through fourth electrical conductors, and has a greater resistivity than both the second and fourth conductors, the sixthelectrical conductor adjacent to the fifth electrical conductor, wherein the sixth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through fifth electrical conductors, and has a lower resistivity than the first, third, and fifth electrical conductors, the seventh electrical conductor adjacent to the sixth electrical conductor, wherein the seventh electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through sixth electrical conductors, and has a greater resistivity than the second, fourth, and sixth conductors, and the eighth electrical conductor adjacent to the seventh electrical conductor, wherein the eighth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through seventh electrical conductors, and has a lower resistivity than the first, third, fifth, and seventh electrical conductors.

[0056] An eleventh aspect may include either the ninth or tenth aspects, wherein the first conductor, the third conductor, or both comprise a resistivity of from 10 pQ.m to 200 pQ.m; and the second conductor comprises a resistivity of from 1 pQ.rn to 2 pQ.m.

[0057] A twelfth aspect may include any one of the ninth through eleventh aspects, wherein the first conductor, the third conductor, or both comprise silicon carbide, molybdenum silicide, a composite of zirconium diboride and silicon carbide, graphite, or combinations thereof; the second conductor comprises a Ni-Cr alloy; or combinations thereof.

[0058] A thirteenth aspect may include any one of the ninth through twelfth aspects, wherein the first conductor, the third conductor, or both have an average heat flux of from 70 kW / m2to 140 kW / m2; and the second conductor has an average heat flux of from 1 kW / m2to 20 kW / m2.

[0059] A fourteenth aspect may include any one of the ninth through thirteenth aspects, and may further comprise a vessel defined by a first end, a second end, and at least one side wall extending from the first end to the second end, the channel positioned between the first end and the second end of the vessel; an electrical insulation material positioned along an exterior of the channel, wherein the first and second pluralities of conductors are positioned along an exterior of the electrical insulation material; an electrical lead line configured to provide direct electrical current to the first conductor, the second conductor, the third conductor, or combinations thereof, wherein the electrical lead line coupled to an electrical power source; or combinations thereof.

[0060] A fifteenth aspect of the present disclosure may comprise a reactor system for upgrading a hydrocarbon-containing feed comprising: a channel comprising an inlet and an outlet, the channel configured to receive the hydrocarbon-containing feed; a first electrical conductor configured to transfer heat to the channel; a second electrical conductor adjacent to the first electrical conductor, the second electrical conductor configured to transfer heat to the channel and electrically connected to the first electrical conductor; and a third electrical conductor adjacent to the second electrical conductor, the third electrical conductor configured to transfer heat to the channel and electrically connected to at least one of the first electrical conductor and the second electrical conductor, wherein the first and third electrical conductors have a greater heat flux than the second conductor, a heat flux ratio between the first and second conductors is from 3:1 to 140:1, and a heat flux ratio between the third and second conductors is from 3: 1 to 140:1.

Claims

AMENDED CLAIMS received by the International Bureau on 28 April 2025 (28.04.2025)1. A reactor system for upgrading a hydrocarbon-containing feed comprising: a channel comprising an inlet, an outlet, and a length of the channel defined between the inlet and outlet, the least one channel configured to receive the hydrocarbon-containing feed; a first electrical conductor configured to transfer heat to the channel; a second electrical conductor positioned adjacent to the first electrical conductor along the length of the channel, the second electrical conductor configured to transfer heat to the channel and electrically connected to the first electrical conductor; a third electrical conductor positioned adjacent to the second electrical conductor along the length of the channel, the third electrical conductor configured to transfer heat to the channel and electrically connected to at least one of the first electrical conductor and the second electrical conductor, wherein the first through third electrical conductors are not in direct contact with the channel, the first and third electrical conductors have a greater resistivity than the second conductor, a resistivity ratio between the first electrical conductor and second electrical conductor is from 8: 1 to 200: 1, and a resistivity ratio between the third electrical conductor and second electrical conductor is from 8: 1 to 200: 1.

2. The reactor system of claim 1, further comprising: a fourth electrical conductor positioned adjacent to the third electrical conductor along the length of the channel, wherein the fourth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through third electrical conductors, and has a lower resistivity than both the first and third electrical conductors; a fifth electrical conductor positioned adjacent to the fourth electrical conductor along the length of the channel, wherein the fifth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through fourth electrical conductors, and has a greater resistivity than both the second and fourth conductors; a sixth electrical conductor positioned adjacent to the fifth electrical conductor along the length of the channel, wherein the sixth electrical conductor is configured to transfer heat to thechannel, is electrically connected to at least one of the first through fifth electrical conductors, and has a lower resistivity than the first, third, and fifth electrical conductors; a seventh electrical conductor positioned adjacent to the sixth electrical conductor along the length of the channel, wherein the seventh electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through sixth electrical conductors, and has a greater resistivity than the second, fourth, and sixth conductors; and an eighth electrical conductor positioned adjacent to the seventh electrical conductor along the length of the channel, wherein the eighth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through seventh electrical conductors, and has a lower resistivity than the first, third, fifth, and seventh electrical conductors.

3. The reactor system of any previous claim, wherein: the first electrical conductor, the third electrical conductor, or both comprise a resistivity of greater than 10 pQ m; and the second electrical conductor comprises a resistivity of from 1 pQ m to 2 pQ m.

4. The reactor system of any previous claim, wherein: the first electrical conductor, the third electrical conductor, or both comprise silicon carbide, molybdenum silicide, a composite of zirconium diboride and silicon carbide, graphite, or combinations thereof; the second electrical conductor comprises a Ni-Cr alloy; or both.

5. The reactor system of any previous claim, wherein: the first electrical conductor, the third electrical conductor, or both have an average heat flux of from 70 kW / m2to 140 kW / m2; and the second electrical conductor has an average heat flux of from 1 kW / m2to 20 kW / m2.

6. The reactor system of any previous claim, wherein the first electrical conductor, the second electrical conductor, the third electrical conductor, or combinations thereof have an average thickness of from 0.01 meters to 0.1 meters.

7. The reactor system of any previous claim, further comprising: an electrical insulation material positioned along the length of the channel about an exterior of the channel, wherein the first, second, and third electrical conductors are positioned along an exterior of the electrical insulation material; a vessel defined by a first end, a second end, and at least one side wall extending from the first end to the second end, the channel positioned between the first end and the second end of the vessel; an electrical lead line configured to provide direct electrical current to the first electrical conductor, the second electrical conductor, the third electrical conductor, or combinations thereof, wherein the electrical lead line is coupled to an electrical power source; or combinations thereof.

8. The reactor system of any previous claim, wherein: a ratio of the length of the first electrical conductor to the second electrical conductor is from 1 : 1 to 4: 1; a ratio of the length of the third electrical conductor to the second electrical conductor is from 1 : 1 to 4: 1; or both.

9. A process of upgrading a hydrocarbon-containing feed utilizing a reactor system, the process comprising: introducing the hydrocarbon-containing feed into a channel of the reactor system, the channel comprising an inlet, an outlet, and a length of the channel defined between the inlet and outlet, the reactor system also comprising a first electrical conductor, a second electrical conductor, and a third electrical conductor, wherein the first through third conductors are configured to transfer heat to the channel, the first electrical conductor is positioned adjacent to the second electrical conductor along the length of the channel and is electrically connected to the second electrical conductor, the third electrical conductor is positioned adjacent to the second electrical conductor along the length of the channel and is electrically connected to the second electrical conductor,a resistivity ratio between the first electrical conductor and second electrical conductor is from 8: 1 to 200: 1, and a resistivity ratio between the third electrical conductor and second electrical conductor is from 8: 1 to 200: 1; applying electrical current to the first, second, and third electrical conductors, wherein the first and third electrical conductors have a greater resistance than the second electrical conductor; and alternatively heating the hydrocarbon-containing feed with greater and lesser degrees of heat along the length of the channel to form an effluent stream.

10. The process of claim 9, further comprising: applying electrical current to fourth, fifth, sixth, seventh, and eighth electrical conductors; and alternatively heating the hydrocarbon-containing feed with greater and lesser degrees of heat along the length of the channel to form an effluent stream, wherein the reactor system further comprises: the fourth electrical conductor positioned adjacent to the third electrical conductor along the length of the channel, wherein the fourth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through third electrical conductors, and has a lower resistivity than both the first and third electrical conductors, the fifth electrical conductor positioned adjacent to the fourth electrical conductor along the length of the channel, wherein the fifth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through fourth electrical conductors, and has a greater resistivity than both the second and fourth conductors, the sixth electrical conductor positioned adjacent to the fifth electrical conductor along the length of the channel, wherein the sixth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through fifth electrical conductors, and has a lower resistivity than the first, third, and fifth electrical conductors,the seventh electrical conductor positioned adjacent to the sixth electrical conductor along the length of the channel, wherein the seventh electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through sixth electrical conductors, and has a greater resistivity than the second, fourth, and sixth conductors, and the eighth electrical conductor positioned adjacent to the seventh electrical conductor along the length of the channel, wherein the eighth electrical conductor is configured to transfer heat to the channel, is electrically connected to at least one of the first through seventh electrical conductors, and has a lower resistivity than the first, third, fifth, and seventh electrical conductors.

11. The process of either of claims 9 or 10, wherein: the first electrical conductor, the third electrical conductor, or both comprise a resistivity of from 10 pQ.m to 200 pQ.m; and the second electrical conductor comprises a resistivity of from 1 pQ.m to 2 pQ.m.

12. The process of either of any of claims 9 through 11, wherein: the first electrical conductor, the third electrical conductor, or both comprise silicon carbide, molybdenum silicide, a composite of zirconium diboride and silicon carbide, graphite, or combinations thereof; the second electrical conductor comprises a Ni-Cr alloy; or combinations thereof.

13. The process of any of claims 9 through 12, wherein: the first electrical conductor, the third electrical conductor, or both have an average heat flux of from 70 kW / m2to 140 kW / m2; and the second electrical conductor has an average heat flux of from 1 kW / m2to 20 kW / m2.

14. The process of any of claims 9 through 12, wherein the reactor system further comprises: a vessel defined by a first end, a second end, and at least one side wall extending from the first end to the second end, the channel positioned between the first end and the second end of the vessel;an electrical insulation material positioned along the length of the channel about an exterior of the channel, wherein the first and second pluralities of electrical conductors are positioned along an exterior of the electrical insulation material; an electrical lead line configured to provide direct electrical current to the first electrical conductor, the second electrical conductor, the third electrical conductor, or combinations thereof, wherein the electrical lead line coupled to an electrical power source; or combinations thereof.

15. A process of upgrading a hydrocarbon-containing feed utilizing a reactor system, the process comprising: introducing the hydrocarbon-containing feed into a channel of the reactor system, the channel comprising an inlet, an outlet, and a length of the channel defined between the inlet and outlet, the reactor system also comprising a first electrical conductor, a second electrical conductor, and a third electrical conductor, wherein the first through third conductors are configured to transfer heat to the channel, the first electrical conductor is positioned adjacent to the second electrical conductor along the length of the channel and is electrically connected to the second electrical conductor, the third electrical conductor is positioned adjacent to the second electrical conductor along the length of the channel and is electrically connected to the second electrical conductor, a heat flux ratio between the first and second conductors is from 3 : 1 to 140: 1, and a heat flux ratio between the third and second conductors is from 3 : 1 to 140: 1 ; applying electrical current to the first, second, and third electrical conductors, wherein the first and third electrical conductors have a greater heat flux than the second electrical conductor; and alternatively heating the hydrocarbon-containing feed with greater and lesser degrees of heat along the length of the channel to form an effluent stream.STATEMENT UNDER ARTICLE 19 (1)The amendments to claim 1 are supported in the application as filed at leastand FIG. 1 for “a channel comprising an inlet, an outlet, and a length of the channel defined between the inlet and outlet”. Further “a second electrical conductor positioned adjacent to the first electrical conductor along the length of the channel” is supported in the application as filed at least at [0041] and FIG.

1. Similarly, “a third electrical conductor positioned adjacent to the second electrical conductor along the length of the channel” supported in the application as filed at least at [0041] and FIG.

1. Similarly, the amendments to claim 2 regarding the fourth, fifth, sixth, seventh, and eighth electrical conductors are supported in the application as filed at least at 5[ [0041] and FIG. 1.The amendments to claims 3-5 and 7-9 are clearly supported in claim 1 as originally filed, particularly in regards to the first, second, and third electrical conductors definitions in claim 1 as now referenced in claims 3-5 and 7-9.Further, the amendment to claim 7, particularly “an electrical insulation material positioned along the length of the channel about an exterior of the channel”, are supported in the application as filed at least at[0022]; [0041]; and FIG. 1.The amendments to claim 9 are supported in the application as filed at least atand FIG. 1 for “a channel comprising an inlet, an outlet, and a length of the channel defined between the inlet and outlet”. Further “a first electrical conductor positioned adjacent to the second electrical conductor along the length of the channel” and “a third electrical conductor positioned adjacent to the second electrical conductor along the length of the channel” are supported in the application as filed at least at [0041] and FIG. 1 .Similarly, the amendments to claim 10 regarding the fourth, fifth, sixth, seventh, and eighth electrical conductors are supported in the application as filed at least at [0041] and FIG. 1.The amendments to claims 11-14 are clearly supported in claim 1 as originally filed, particularly in regards to the first, second, and third electrical conductors definitions in claim 9 as now referenced in claims 11-14.New claim 15 is supported in the application as filed at least at[0054]; [0026]; [0011]; and [0041], and FIG. 1.By the present amendment, the Applicants respectfully submit that all of the claims are now clear, novel, inventive, and industrially applicable.

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