Crude Oil Conversion via Aromatic Ring Opening for Propylene Yield
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Solution Overview
Problem
Conventional integrated processes for converting crude oil into petrochemicals and fuels have a low propylene yield and produce significant amounts of fuel, limiting the production of high-value petrochemicals.
Innovation Solution
The process involves crude oil distillation followed by aromatic ring opening of kerosene and gasoil to produce LPG, which is then subjected to olefins synthesis, improving propylene yield and reducing by-product complexity, thereby enhancing petrochemical production at the expense of fuel production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional integrated processes are used to convert crude oil into petrochemicals and fuels, then fuel production is maintained, but propylene yield is low and petrochemical production is limited
Solution Approach 1:
The process segments the crude oil conversion into distinct functional units: crude distillation unit, aromatic ring opening unit, and olefins synthesis unit. This segmentation allows each unit to be optimized for its specific function, with the aromatic ring opening unit specifically designed to convert aromatic hydrocarbons to LPG, which is then converted to olefins, thereby maximizing propylene yield while minimizing fuel production
Solution Approach 2:
The process applies preliminary action by first converting aromatic hydrocarbons to LPG through aromatic ring opening before subjecting the LPG to olefins synthesis. This preliminary conversion step is crucial because it transforms the feedstock into a more suitable form for high-yield propylene production, thereby resolving the contradiction between fuel and petrochemical production
2Productivity
If crude oil fractions are subjected directly to steam cracking, then fuel production occurs, but propylene yield and petrochemical production are limited
Solution Approach 1:
The process performs preliminary conversion of aromatic hydrocarbons to LPG through aromatic ring opening before the olefins synthesis step. This preliminary action simplifies the downstream fractionation section because the feed to the olefins synthesis unit is already in the form of LPG with fewer complex aromatic components, thereby reducing by-product formation and fractionation complexity while enhancing petrochemical production
Solution Approach 2:
LPG serves as an intermediary substance in the process. The aromatic ring opening unit converts aromatic hydrocarbons to LPG, which then acts as the feedstock for the olefins synthesis unit. This intermediary role of LPG simplifies the overall process by providing a standardized, manageable feedstock for olefins synthesis, thereby reducing fractionation section complexity and enhancing petrochemical production efficiency
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 significantly increases the propylene yield and reduces the production of fuels, leading to a more efficient conversion of crude oil into high-value petrochemicals with improved capital efficiency and hydrogen balance.
Implementation Method 1
subjecting a hydrocarbon feed to aromatic ring opening to produce LPG
Implementation Method 2
subjecting the LPG produced in the integrated process to olefins synthesis
Implementation Method 3
crude oil distillation
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to an integrated process to convert crude oil into petrochemical products comprising crude oil distillation, aromatic ring opening, and olefins synthesis, which process comprises subjecting a hydrocarbon feed to aromatic ring opening to produce LPG and subjecting the LPG produced in the integrated process to olefins synthesis. Furthermore, the present invention relates to a process installation to convert crude oil into petrochemical products comprising a crude distillation unit comprising an inlet for crude oil and at least one outlet for kerosene and/or gasoil; an aromatic ring opening unit comprising an inlet for a hydrocarbon feed to aromatic ring opening and an outlet for LPG; and a unit for the olefins synthesis comprising an inlet for LPG produced by the integrated petrochemical process installation and an outlet for olefins. The hydrocarbon feed subjected to aromatic ring opening comprises kerosene and/or gasoil produced by crude oil distillation in the process; and refinery unit-derived middle-distillate produced in the process. The process and the process installation of the present invention have an increased production of petrochemicals at the expense of the production of fuels and an improved propylene yield.