Crude Oil Conversion Process for BTX Yield via Segmentation
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Solution Overview
Problem
Conventional methods for integrating oil refinery operations with downstream chemical plants produce significant amounts of fuel and have a relatively low BTX yield, limiting the production of high-value petrochemicals.
Innovation Solution
An integrated process that includes crude oil distillation, reforming, dearomatization, fluid catalytic cracking, and aromatic ring opening to enhance the production of petrochemicals by specifically subjecting naphtha to catalytic reforming, kerosene and gasoil to pyrolysis or fluid catalytic cracking, and aromatic hydrocarbons to aromatic ring opening, followed by gasoline treatment to produce BTX.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional integration methods are used to convert crude oil to petrochemicals, then fuel production is maintained, but BTX yield remains relatively low
Solution Approach 1:
The crude oil feedstock is segmented into different boiling range fractions (naphtha, kerosene, gasoil) through distillation, with each fraction directed to specific conversion processes optimized for BTX production. Naphtha goes to reforming, while kerosene and gasoil undergo dearomatization followed by selective processing of aromatic and aliphatic streams, thereby maximizing overall BTX yield from the crude oil feed.
2Quantity of substance
If naphtha is subjected to catalytic reforming, then reformer gasoline is produced, but the process complexity increases
Solution Approach 1:
The patent combines multiple conversion processes (catalytic reforming of naphtha, dearomatization of kerosene/gasoil, pyrolysis or FCC of aliphatic streams, and hydrocracking of aromatic streams) into an integrated flow scheme. This merging allows the different streams to be processed simultaneously and their products combined, achieving high BTX yield while managing process complexity through systematic integration rather than isolated units.
3Quantity of substance
If kerosene and gasoil are subjected to dearomatization followed by pyrolysis or fluid catalytic cracking, then pyrolysis gasoline or FCC gasoline is produced, but energy consumption increases
Solution Approach 1:
The patent applies different processing conditions and catalysts tailored to specific feedstock streams and desired products. For example, pyrolysis is used for aliphatic-rich streams to maximize olefin and aromatic production, while hydrocracking is applied to aromatic-rich streams for BTX production. This localized optimization of process conditions for each stream minimizes overall energy consumption while maximizing BTX yield from the combined feedstock.
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 BTX yield and reduces fuel production, improving the carbon efficiency and value of petrochemical products derived from crude oil.
Implementation Method 1
subjecting naphtha to reforming to produce reformer gasoline
Implementation Method 2
subjecting the stream enriched for alkanes and naphthenes to pyrolysis to produce a pyrolysis gasoline
Implementation Method 3
subjecting the stream enriched for aromatics to aromatic ring opening to produce ARO gasoline
Implementation Method 4
subjecting crude oil to crude oil distillation to produce naphtha and one or more of kerosene and gasoil
Data Source
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AI summary
The present invention relates to an integrated process to convert crude oil into petrochemical products comprising crude oil distillation, reforming, dearomatization, fluid catalytic cracking and aromatic ring opening, which process comprises: subjecting crude oil to crude oil distillation to produce naphtha and one or more of kerosene and gasoil; subjecting naphtha to reforming to produce reformer gasoline; subjecting kerosene and/or gasoil to dearomatization to produce a first stream enriched for alkanes and naphthenes and a second stream enriched for aromatics; subjecting the stream enriched for alkanes and naphthenes to pyrolysis to produce a pyrolysis gasoline or to fluid catalytic cracking to produce a FCC gasoline; subjecting the stream enriched for aromatics to aromatic ring opening to produce a ARO gasoline; and subjecting one or more of reformer gasoline, FCC gasoline and ARO gasoline to gasoline treatment to produce BTX. Furthermore, the present invention relates to a process installation to convert crude oil into petrochemical products using the process of the present invention. 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 BTX yield.