Integrated Crude Oil Conversion Process for Petrochemical Yield
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Solution Overview
Problem
Existing processes for converting crude oil into petrochemical products often compromise on carbon efficiency, ethylene yield, and ethylene:propylene ratio, with reduced yields of butadiene and benzene.
Innovation Solution
An integrated process involving crude oil distillation, resid upgrading, middle-distillate hydrocracking, and steam cracking, which includes subjecting middle-distillate and hydrowax to hydrocracking and subsequent steam cracking to optimize carbon efficiency and yield of valuable petrochemicals like ethylene, propylene, butadiene, and benzene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing processes for converting crude oil into petrochemical products are used, then the conversion process is simpler, but carbon efficiency is compromised and ethylene yield is reduced
Solution Approach 1:
The crude oil conversion process is divided into multiple distinct stages: crude oil distillation to separate fractions, selective hydrocracking of middle-distillate and gasoil, steam cracking of the hydrocracked products, and catalytic reforming. Each stage is optimized independently to maximize carbon efficiency while maintaining manageable complexity through modular processing units.
Solution Approach 2:
The process integrates multiple conversion pathways by combining hydrocracking and steam cracking units in an integrated configuration. The hydrocracked middle-distillate and gasoil streams are merged and subjected to steam cracking together, allowing synergistic optimization of carbon efficiency across the entire conversion train while sharing common infrastructure.
2Quantity of substance
If existing processes are used, then the process configuration is simpler, but ethylene yield and ethylene:propylene ratio are reduced
Solution Approach 1:
The process applies selective hydrocracking conditions tailored to specific feedstocks: middle-distillate is hydrocracked under conditions optimized for its composition, while gasoil is hydrocracked under separate optimized conditions. This local optimization of cracking parameters for different feed types maximizes ethylene yield and controls the ethylene:propylene ratio in the final product.
Solution Approach 2:
The process utilizes parameter changes in the hydrocracking and steam cracking stages to optimize ethylene production. By adjusting temperature, pressure, residence time, and catalyst composition in the hydrocracking unit, and subsequently in the steam cracking unit, the process maximizes ethylene yield while controlling the ethylene:propylene ratio to meet product specifications.
3Quantity of substance
If existing processes are used, then the number of processing stages is reduced, but yields of butadiene and benzene are reduced
Solution Approach 1:
The process performs preliminary hydrocracking of middle-distillate and gasoil before steam cracking to prepare the feed composition for optimal butadiene and benzene formation. This preliminary action modifies the molecular structure and distribution of the feedstock, creating conditions that favor high yields of desired aromatic and olefin products in the subsequent steam cracking stage.
Solution Approach 2:
The integrated process maintains continuous conversion through the sequence of hydrocracking followed by steam cracking, with intermediate products flowing continuously from one unit to the next. This continuity ensures maximum utilization of carbon atoms throughout the process, minimizing losses and maximizing the yield of valuable products including butadiene and benzene across the entire conversion train.
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 process achieves high carbon efficiency while maintaining a favorable ethylene:propylene ratio and improving yields of butadiene and benzene, enhancing the overall conversion of crude oil into high-value petrochemical products.
Implementation Method 1
subjecting the crude oil to crude oil distillation to produce gases fraction, naphtha, kerosene, gasoil and resid
Implementation Method 2
subjecting resid to resid upgrading to produce LPG, light-distillate and middle-distillate
Implementation Method 3
subjecting at least a portion of one or more of the group consisting of middle-distillate produced by resid upgrading, kerosene and gasoil to middle-distillate hydrocracking to produce LPG, light-distillate and hydrowax
Implementation Method 4
subjecting at least a portion of one or more of the group consisting of light-distillate produced by resid upgrading, light-distillate produced by middle-distillate hydrocracking and hydrowax to steam cracking
Data Source
AI summary
An integrated process to convert crude oil into petrochemical products includes distilling crude oil to produce gases fraction, naphtha, kerosene, gasoil and resid; subjecting resid to resid upgrading to produce LPG, light-distillate and middle-distillate; subjecting at least a portion of one or more of the group consisting of middle-distillate produced by resid upgrading, kerosene and gasoil to middle-distillate hydrocracking to produce LPG, light-distillate and hydrowax; and subjecting at least a portion of one or more of the group consisting of light-distillate produced by resid upgrading, light-distillate produced by middle-distillate hydrocracking and hydrowax to steam cracking. A process installation for performing the process is also provided.