Integrated Crude Conditioning and Steam Cracking Process
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Solution Overview
Problem
Existing processes for converting whole crudes and heavy hydrocarbon streams to produce olefins and aromatics face challenges such as high operational costs due to the removal of high-boiling compounds, which form coke and require additional processing steps, and the difficulty in converting vacuum residue without forming detrimental HPNAs.
Innovation Solution
A process involving the separation of whole crude into light, medium, and high boiling fractions, followed by processing the high boiling residue fraction in a solvent deasphalting unit and hydroprocessing the pitch fraction in an ebullated bed residue hydrocracking unit, to produce a steam crackable hydrocarbon stream.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If high-boiling compounds are removed before steam cracking, then coke formation is reduced, but capital cost increases and profitability decreases
Solution Approach 1:
The patent converts the harmful high-boiling compounds (which cause coke formation) into valuable petrochemical products through catalytic cracking. Instead of removing these compounds before steam cracking, the process uses a catalyst to selectively convert them into desired products, thereby eliminating the harmful effect while creating economic value.
Solution Approach 2:
The patent applies preliminary catalytic treatment to the heavy hydrocarbon stream before steam cracking. The catalyst is introduced in advance to modify the feedstock properties, reducing coke formation propensity and improving the performance of downstream steam cracking equipment without requiring complex removal units.
2Reliability
If high-boiling compounds are removed before steam cracking, then operational issues are reduced, but operational costs increase
Solution Approach 1:
The patent transforms the operational burden of handling high-boiling compounds into an opportunity by using catalytic cracking to convert them into valuable petrochemicals. This approach maintains operational reliability by managing the compounds through a controlled catalytic process rather than requiring their removal, thereby avoiding additional operational costs.
3Object-affected harmful factors
If vacuum residue is converted without significant HPNA formation, then steam cracker performance is improved, but conversion efficiency is reduced
Solution Approach 1:
The patent changes the chemical parameters of vacuum residue through catalytic treatment, modifying the molecular structure to reduce HPNA formation while maintaining high conversion efficiency. The catalyst facilitates selective reactions that transform the feedstock properties, achieving both reduced harmful byproducts and efficient conversion.
Solution Approach 2:
The patent introduces a catalyst as an intermediary substance that mediates the conversion of vacuum residue. The catalyst facilitates the transformation process, enabling high conversion efficiency while controlling the formation of harmful HPNAs by providing alternative reaction pathways.
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 efficiently converts heavy hydrocarbon streams into high-value petrochemicals, minimizing the formation of coke and HPNAs, and increasing the yield of olefins and aromatics while reducing capital and operational costs.
Implementation Method 1
processing the high boiling residue fraction in a solvent deasphalting unit to produce a deasphalted oil fraction and a pitch fraction
Implementation Method 2
hydroprocessing the pitch fraction in an ebullated bed residue hydrocracking unit to produce a steam crackable hydrocarbon stream
Implementation Method 3
hydroprocessing the pitch fraction in an ebullated bed residue hydrocracking unit
Implementation Method 4
steam cracking to convert hydrocarbons therein into one or more light olefins, a C5+ fraction, and a pyrolysis oil
Data Source
AI summary
Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into at least light and heavy fractions. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a solvent deasphalting unit, or an ebullated bed hydrocracking unit. Products from the upgrading operations may be used as feed to a steam cracker.