Integrated Crude Conversion to Olefins and BTX
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Solution Overview
Problem
Existing refining systems do not maximize the market value from crude oil streams, resulting in an undesirable volume of lower value products during the production of light olefins and BTX (benzene, toluene, and xylenes).
Innovation Solution
An integrated process and system that optimizes the conversion of crude oil to light olefins and BTX by separating hydrocarbon streams into specific fractions, which are then processed through a series of unit operations including solvent deasphalting, delayed coking, hydrotreating, cracking, and aromatization to produce BTX and light olefins efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing refining systems are used to produce light olefins and BTX, then production can be achieved, but the market value from crude oil streams is not maximized and an undesirable volume of lower value products is generated
Solution Approach 1:
The crude oil feedstock is segmented into different boiling range fractions (light crude fraction boiling at ≤210°C and heavy crude fraction boiling at >210°C) which are then selectively routed to different reactor units optimized for producing either light olefins or BTX, thereby maximizing the yield of high-value products while minimizing low-value byproducts
Solution Approach 2:
Different reactor units are assigned different feedstock qualities matched to their optimal conversion capabilities: steam crackers receive light crude fraction for light olefin production, while catalytic reformers receive specific fractions for BTX production, optimizing local conversion efficiency and product value
2Productivity
If crude oil is converted to light olefins and BTX using conventional processes, then production occurs, but the conversion efficiency and market value maximization are not achieved
Solution Approach 1:
Multiple refining and petrochemical processing units (feed separator, solvent deasphalting unit, delayed coker, hydrotreaters, steam crackers, catalytic reformers, aromatization units) are merged into an integrated system where crude oil is simultaneously converted to multiple high-value products (light olefins, BTX, petroleum coke) through coordinated processing, achieving high conversion efficiency despite system complexity
Solution Approach 2:
The integrated system performs multiple functions simultaneously: separation, deasphalting, cracking, hydrotreating, reforming, and aromatization, allowing a single processing complex to maximize the value of crude oil by producing multiple high-value petrochemical products from different feedstock fractions
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 system effectively increases the yield of light olefins and BTX, maximizing the value of crude oil by optimizing each unit operation and recycling streams for further processing, thereby enhancing the production of valuable petrochemicals.
Implementation Method 1
separate the hydrocarbon stream into a light crude fraction boiling at a first temperature or less and a heavy crude fraction boiling at greater than the first temperature
Implementation Method 2
residue heavy components having a boiling point above 300° C. and asphaltenes are removed from the heavy crude fraction
Implementation Method 3
the pitch product undergoes a thermal cracking reaction to obtain solid petroleum coke and a delayed coker product stream
Implementation Method 4
the light crude fraction, the deasphalted oil product, and the delayed coker product stream are hydrotreated to remove heteroatoms and saturate carbon-carbon bonds
Implementation Method 5
the C2-C4 fraction is cracked to generate a steam cracker product stream comprising light olefins and aromatics
Implementation Method 6
the aromatization unit converts aliphatic hydrocarbons in the hydrotreated light fraction to aromatics
Implementation Method 7
the hydrotreated heavy fraction is cracked to generate a SECC product stream comprising light olefins
Data Source
AI summary
An integrated process and associated system for conversion of crude oil to value added petrochemicals. The process includes separating crude oil into light and heavy crude fractions and processing the heavy fraction in a solvent deasphalting unit and a delayed coker unit, and then providing the light fraction and selected effluents of the solvent deasphalting unit and the delayed coker unit to a hydrotreater. The process further includes separating the effluent of the hydrotreater to generate a C1 fraction passed to a methane cracker, a C2-C4 fraction passed to a steam cracker, a hydrotreated light fraction passed to an aromatization unit, and a hydrotreated heavy fraction passed to a steam enhanced catalytic cracking unit. The process further includes separating effluents of the methane cracker, the steam cracker, the aromatization unit, and the steam enhanced catalytic cracking unit into product streams including a BTX stream and a light olefin stream.