Integrated Crude Distillation and Cracking for Refinery Cost Reduction
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Solution Overview
Problem
Oil refineries are expensive to build and operate due to the need for extensive equipment, necessitating a reduction in equipment count to lower installation and operating costs while maintaining hydrocarbon production capabilities.
Innovation Solution
The method involves fractionating crude oil to produce a saturated stream and a residual stream, which are then combined and further processed using cracking devices to produce unsaturated streams, subsequently co-processed to reduce equipment requirements, including the use of fluid catalytic cracking units and hydrocracking processes to generate refined hydrocarbon products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional oil refining apparatuses with multiple process units are used, then hydrocarbon production capability is maintained, but installation and operating costs are prohibitive
Solution Approach 1:
The patent combines multiple process units into integrated configurations where a single crude distillation unit feeds both a fluid catalytic cracking unit and a hydrocracking unit, which then combine their product streams. This merging reduces the total number of independent process units while maintaining full refining capability across different hydrocarbon product lines.
Solution Approach 2:
The patent creates a multi-functional refining system where the crude distillation unit serves as a common feed source for multiple cracking processes, and the product streams from different cracking units are combined and co-processing. This universal configuration allows one set of equipment to perform multiple refining functions that traditionally required separate dedicated units.
2Ease of manufacture
If traditional oil refining apparatuses with multiple process units are used, then hydrocarbon production capability is maintained, but operating expenses are high
Solution Approach 1:
The patent merges the product streams from fluid catalytic cracking and hydrocracking units into a common processing path, combining previously separate operating costs into a shared infrastructure. This reduces duplicate equipment operations and lowers overall operating expenses while maintaining the production flexibility of multiple cracking processes.
Solution Approach 2:
The unified product stream handling system serves multiple cracking unit outputs through a single processing path, creating a multi-functional downstream system that reduces the need for separate handling, storage, and distribution equipment for each cracking product, thereby lowering operating costs.
3Adaptability or versatility
If extensive refinery equipment is used, then complete hydrocarbon processing capability is achieved, but equipment count increases
Solution Approach 1:
The patent segments the cracking functions into specialized units (fluid catalytic cracking and hydrocracking) that process different feedstock types and produce different product qualities, then combines their outputs. This segmentation allows each unit to be optimized for its specific function while the combined system provides comprehensive processing capability without requiring every possible unit type.
Solution Approach 2:
The patent combines the output streams from specialized cracking units with a common distillation and fractionation system, merging multiple processing paths into a unified downstream handling system. This reduces the total equipment count by eliminating redundant separation and handling equipment while maintaining the ability to process diverse hydrocarbon feeds and produce multiple product types.
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 approach reduces the number of process units needed, lowering costs while effectively producing hydrocarbon fuels with improved equipment efficiency and reduced operational expenses.
Implementation Method 1
fractionating a crude oil feedstock to produce a crude saturated stream and a residual stream
Implementation Method 2
The residual stream is cracked in a cracking device to produce an unsaturated stream
Implementation Method 3
hydrocracking a hydrocracker feedstock to produce a hydrocracker saturated stream
Data Source
AI summary
Methods and oil refinery apparatuses are provided for producing hydrocarbons. A method includes fractionating a crude oil feedstock to produce a crude saturated stream and a residual stream. The residual stream is cracked in a cracking device to produce an unsaturated stream, and the unsaturated stream and the crude saturated stream are combined to produce a combined stream. The combined stream is fractionated to produce a refinery fuel gas stream.