Catalytic Cracking Char Recovery for Energy Reduction
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Solution Overview
Problem
Current processes for catalytically cracking a mixture of pyrolysis effluent and hydrocarbon streams require high energy input and result in significant greenhouse gas emissions, particularly when upgrading biofuels like pyrolysis oil, which is energy-intensive and not environmentally friendly.
Innovation Solution
Recovering and utilizing char generated during the catalytic cracking process to provide energy, either by mixing it with a liquid fuel to create a slurry fuel or drying and burning it, thereby reducing energy consumption and emissions by using a renewable resource.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperatures are used for catalytic cracking of pyrolysis effluent and hydrocarbon streams, then cracking conversion is improved, but energy consumption increases
Solution Approach 1:
The patent converts the harmful effect of high energy consumption into a benefit by recovering char from the cracking effluent and combusting it to generate heat. This recovered heat is then used to preheat the feed streams entering the catalytic cracking zone, creating a self-sustaining energy system that reduces external energy requirements while maintaining high cracking conversion.
Solution Approach 2:
The patent implements preliminary heating of the feed streams using heat recovered from char combustion before the streams enter the catalytic cracking zone. This preheating action reduces the energy demand of the main cracking process by preparing the feed at elevated temperatures in advance, thereby improving cracking conversion while reducing overall energy consumption.
2Productivity
If conventional catalytic cracking processes are used for upgrading biofuels, then fuel upgrading is achieved, but greenhouse gas emissions increase
Solution Approach 1:
The patent converts the harmful greenhouse gas emissions into a beneficial resource by capturing char (a carbon-containing byproduct) from the cracking effluent and combusting it to generate process heat. This internal heat generation reduces the need for external fossil fuel combustion, thereby maintaining fuel upgrading productivity while significantly reducing net greenhouse gas emissions.
Solution Approach 2:
The patent creates a self-service energy system where the cracking process itself generates the heat it needs through char combustion. The char produced during cracking is recovered and burned to provide heat for feed preheating, making the process self-sustaining and reducing dependence on external energy sources that would generate additional emissions.
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
The use of char as a heat source lowers energy requirements and greenhouse gas emissions in the catalytic cracking zone, enhancing the efficiency and sustainability of the process while utilizing a renewable resource.
Implementation Method 1
burning the dried char
Implementation Method 2
providing energy to the catalytic cracking zone with the recovered char
Implementation Method 3
a hydrocarbon stream is contacted with a particulate cracking catalyst under conditions that are suitable for converting the relatively high boiling point hydrocarbons to lower boiling point hydrocarbons
Implementation Method 4
organic biomass, such as wood waste, agricultural waste, etc., is rapidly heated to about 450 to about 600° C. (about 842 to about 1112° F.) in the absence of air using a pyrolysis unit
Implementation Method 5
rapidly heated to about 450 to about 600° C. (about 842 to about 1112° F.) in the absence of air
Implementation Method 6
A portion of the pyrolysis vapor stream is condensed in a condensing system to produce a pyrolysis oil stream
Data Source
AI summary
Processes and apparatuses for co-processing pyrolysis effluent and a hydrocarbon stream in which a char produced by the catalytic cracking of the pyrolysis effluent is recovered and utilized to provide energy, such as heat to the catalytic cracking zone. The char can be burned in various combustion zones associated with the catalytic cracking zone. The char is produced from a renewable resource.