Cracker Heat Integration Using HRU and TLE for Lower Emissions
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Solution Overview
Problem
Conventional hydrocarbon cracking furnaces are large, complex, and inefficient, leading to high greenhouse gas emissions and operational costs, with limited means to reduce their size or emissions effectively.
Innovation Solution
Rearrange thermal energy distribution within the hydrocarbon processing facility by integrating heat recovery units and utilizing electrical power, including renewable sources, to optimize heat integration and reduce greenhouse gas emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional steam cracking furnaces are used, then hydrocarbon cracking can be performed, but the furnaces are large, complex, and inefficient leading to high greenhouse gas emissions
Solution Approach 1:
The patent divides the traditional integrated cracking furnace into separate functional units: a cracking reactor for the actual hydrocarbon cracking, a heat recovery unit for thermal energy extraction, and an electrical power supply system. This segmentation allows each component to be optimized independently, reducing overall complexity while maintaining functionality and reducing emissions.
Solution Approach 2:
The patent replaces the traditional mechanical/thermal furnace system with an electrically-driven cracking system. Electrical power is supplied directly to the cracking reactor, eliminating the need for large combustion furnaces and associated thermal management systems, thereby reducing greenhouse gas emissions and operational complexity.
2Use of energy by moving object
If conventional cracking furnaces are used, then hydrocarbon processing can be performed, but energy efficiency is poor and operational costs are high
Solution Approach 1:
The patent converts the thermal energy that would normally be wasted heat into a useful resource. The heat recovery unit captures thermal energy from the cracking process and converts it into electrical power through a heat engine, transforming a loss into a beneficial energy source that reduces operational costs and improves overall efficiency.
Solution Approach 2:
The system is designed to be self-sufficient by generating its own electrical power through the heat recovery unit. The thermal energy from the cracking process drives a heat engine that produces electricity, allowing the facility to power itself and reduce dependence on external energy sources, thereby improving energy efficiency and reducing operational costs.
3Loss of energy
If thermal energy is redistributed through heat recovery units, then energy efficiency improves and emissions reduce, but equipment complexity increases
Solution Approach 1:
The heat recovery unit is designed with multi-functionality, serving both as a thermal energy recovery device and as an electrical power generation source. This universal approach consolidates multiple functions into a single unit, reducing the need for separate equipment and thereby limiting the increase in system complexity while achieving improved energy efficiency and emissions reduction.
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
Achieves a threefold reduction in harmful emissions and improved energy efficiency by redistributing thermal energy, allowing for flexible capacity adjustments and reduced on-site investments.
Implementation Method 1
a cracked gaseous effluent exiting the apparatus is cooled in a transfer line exchanger (TLE) while generating high-pressure steam
Implementation Method 2
heating and/or vaporizing boiler feed water
Implementation Method 3
heating and/or vaporizing boiler feed water
Implementation Method 4
superheating high pressure steam generated in the TLE unit
Implementation Method 5
at least one apparatus for cracking hydrocarbon containing feedstocks
Data Source
AI summary
A process is provided for improving energy efficiency and reducing greenhouse gas emissions in a hydrocarbon processing and/or production facility, through rearrangement of thermal energy distribution within said facility, said facility comprising a cracker unit with at least one apparatus for cracking a hydrocarbon containing feed, in presence of a dilution medium, wherein a cracked gaseous effluent exiting the apparatus is instantly cooled in a transfer line exchanger (TLE) while generating high-pressure steam, in which process any one of the: heating and/or vaporizing the hydrocarbon containing feed and/or the dilution medium, heating and/or vaporizing boiler feed water, and superheating high pressure steam generated in the TLE unit, is conducted in a heat recovery unit (HRU) arranged downstream the TLE, and which process comprises supplying electrical power into the hydrocarbon processing and/or production facility.