Crude-to-Chemicals Integration via Delayed Coking and Hydroprocessing
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Solution Overview
Problem
Current processes for converting crude oil to petrochemicals and fuel products are limited by the availability and quality of feedstocks, leading to high costs and inefficiencies, particularly in the production of lower olefins and aromatics, due to reliance on costly and energy-intensive refining processes.
Innovation Solution
An integrated process involving atmospheric and vacuum distillation, hydroprocessing, steam cracking, and delayed coking to produce naphtha, diesel fuel, and petrochemicals, including ethylene, propylene, and butylenes, while optimizing feedstock utilization and reducing capital expenditures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional steam pyrolysis is used with limited feedstocks like naphtha, then lower olefins and aromatics can be produced, but the process becomes costly and energy-intensive
Solution Approach 1:
The patent changes the physical and chemical parameters of heavy naphtha through hydroprocessing (temperature, pressure, catalyst) to convert it into light naphtha and other valuable products, making previously unsuitable feedstocks viable for steam pyrolysis
Solution Approach 2:
The patent segments heavy naphtha into multiple fractions through vacuum distillation and hydroprocessing, separating it into light naphtha for ethylene production, middle distillates for diesel, and residue for coke, thereby optimizing the use of each fraction
2Quantity of substance
If heavy naphtha is used as feedstock for ethylene production, then feedstock availability is improved, but production quality decreases due to lower paraffin and higher aromatics content
Solution Approach 1:
Hydroprocessing transforms the chemical composition of heavy naphtha by breaking down complex molecules and removing aromatics, changing the feedstock parameters to match the requirements for high-quality ethylene production
Solution Approach 2:
The patent introduces hydroprocessing as an intermediary process between heavy naphtha and steam pyrolysis, using catalysts and controlled reaction conditions to convert heavy naphtha into suitable feedstock for ethylene production
3Productivity
If integrated processing is implemented to convert crude oil to petrochemicals, then economic viability and efficiency are improved, but device complexity increases
Solution Approach 1:
The patent merges multiple processing functions (distillation, hydroprocessing, steam pyrolysis, delayed coking) into an integrated crude-to-chemicals complex, where units share utilities, feedstocks, and products, thereby improving overall efficiency despite increased complexity
Solution Approach 2:
The integrated process design allows processing units to serve multiple functions - for example, the delayed coker produces both petroleum coke and gas oil that can be fed to the hydroprocessing unit, creating flexible multi-functional operations
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 integrated process enhances the conversion of crude oil into valuable petrochemicals and fuels with improved economic viability and efficiency by utilizing multiple processing units to prepare suitable feedstocks for steam cracking, thereby overcoming the limitations of traditional refining methods.
Implementation Method 1
an initial separation step to separate from a crude oil feed in an atmospheric distillation zone
Implementation Method 2
A vacuum gas oil fraction is separated from the atmospheric residue fraction in a vacuum distillation zone
Implementation Method 3
In a distillate hydroprocessing (DHP) zone, such as a diesel hydrotreater, at least a portion of the middle distillates are processed to produce a naphtha fraction and a diesel fuel fraction
Implementation Method 4
The vacuum residue from the vacuum distillation zone is processed in a delayed coking zone
Implementation Method 5
Thermal cracking, or steam pyrolysis, is a major type of process for forming these materials, typically in the presence of steam, and in the absence of oxygen
Data Source
AI summary
Process scheme configurations are disclosed that enable conversion of crude oil feeds with several processing units in an integrated manner into petrochemicals. The designs utilize minimum capital expenditures to prepare suitable feedstocks for the steam cracker complex. The integrated process for converting crude oil to petrochemical products including olefins and aromatics, and fuel products, includes mixed feed steam cracking and gas oil steam cracking. Feeds to the mixed feed steam cracker include light products and naphtha from hydroprocessing zones within the battery limits, recycle streams from the C3 and C4 olefins recovery steps, and raffinate from a pyrolysis gasoline aromatics extraction zone within the battery limits. Feeds to the gas oil steam cracker include gas oil range intermediates from the vacuum gas oil hydroprocessing zone. Furthermore, vacuum residue is processed in a delayed coker unit to produce coker naphtha, which is hydrotreated and passed as additional feed to aromatics extraction zone and/or the mixed feed steam cracker, and coker gas oil range intermediates as additional feed to the gas oil hydroprocessing zone.