C5+ Hydrocarbon Conversion via Phase Segmentation and Recycled Solvents
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Solution Overview
Problem
The existing processes for converting the bottoms product from catalytically cracked effluent into more valuable products are inefficient, requiring excessive hydrogen addition and expensive separation equipment, and often necessitate the use of more valuable hydrocarbons as solvents or diluents.
Innovation Solution
A process involving heating a hydrocarbon feed with an aqueous fluid to produce a heated mixture, separating it into vapor and liquid phases, catalytically cracking the liquid phase, and steam cracking the vapor phase, with subsequent hydroprocessing of the tar and bottoms products to produce a utility fluid that can be used as a quench fluid and solvent, reducing fouling and enhancing product yield and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the bottoms product is converted into more valuable products using conventional processes, then product value is improved, but excessive hydrogen addition and expensive separation equipment are required
Solution Approach 1:
The process segments the bottoms product conversion into two distinct pathways: catalytic cracking for lighter fractions and hydroprocessing for heavier bottoms. This segmentation allows each unit to be optimized for its specific function, avoiding the need for complex integrated separation equipment while improving overall product value through targeted conversion routes.
Solution Approach 2:
The patent introduces an intermediary hydroprocessing unit that processes the bottoms product before further conversion. This intermediary step modifies the chemical composition of the bottoms, making it more suitable for subsequent cracking or blending operations, thereby reducing the complexity of downstream separation equipment while enhancing product value.
2Ease of operation
If more valuable hydrocarbons are used as solvents or diluents to improve bottoms product processability, then processability is improved, but cost increases due to using valuable hydrocarbons
Solution Approach 1:
The process uses itself to solve the processability problem: the lighter hydrocarbon products generated from the catalytic cracking of the bottoms product are recycled and used as solvents/diluents for further processing. This self-service approach eliminates the need to import expensive external hydrocarbons while maintaining improved processability throughout the conversion sequence.
Solution Approach 2:
The patent recycles lighter hydrocarbon fractions that would otherwise be discarded or sold separately. These recovered light hydrocarbons are reused as process solvents and diluents, eliminating the need to purchase expensive external hydrocarbons while maintaining system economy and improving overall processability.
3Productivity
If the bottoms product is processed without hydroprocessing, then process simplicity is maintained, but fouling increases and product yield decreases
Solution Approach 1:
The hydroprocessing unit performs preliminary chemical modification of the bottoms product before it enters the catalytic cracking section. This preliminary hydroprocessing saturates aromatic compounds and modifies molecular structure, preventing coking and fouling reactions that would otherwise occur during cracking. The result is reduced fouling and improved process gas yield without requiring additional complex equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process improves the conversion of bottoms product into more valuable products by reducing fouling, increasing process gas yield, and enhancing the properties of the hydroprocessed tar and heavy products, such as viscosity and blending characteristics, without the need for excessive hydrogen or expensive solvents.
Implementation Method 1
heating a hydrocarbon feed and combining the hydrocarbon feed with an aqueous fluid to produce a heated mixture
Implementation Method 2
separating from the heated mixture a vapor phase product and a liquid phase product
Implementation Method 3
catalytically cracking at least a portion of the liquid phase product in the presence of a fluidized catalyst
Implementation Method 4
catalytically cracking at least a portion of the liquid phase product in the presence of a fluidized catalyst
Implementation Method 5
steam cracking at least a portion of the vapor phase product to produce a steam cracker effluent
Implementation Method 6
hydroprocessing at least a portion of the tar product to produce a hydroprocessed product
Data Source
AI summary
The invention relates to C5+ hydrocarbon conversion. More particularly, the invention relates to separating a vapor phase product and a liquid phase product from a heated mixture that includes steam and C5+ hydrocarbons, catalytically cracking the liquid phase product and steam cracking the vapor phase product.