Integrated Hydroprocessing and Steam Pyrolysis for Crude Oil Conversion
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Solution Overview
Problem
Conventional steam pyrolysis processes using heavy hydrocarbons as feedstocks face issues with coke formation and yield imbalances in producing olefins and aromatics, limiting the efficiency and duration of operations, while also requiring costly and energy-intensive refining steps due to limited availability of light hydrocarbon feedstocks.
Innovation Solution
An integrated hydroprocessing, steam pyrolysis, and catalytic cracking process that processes crude oil feedstocks, reducing contaminants and increasing paraffinicity, which are then thermally cracked in the presence of steam to produce olefins and aromatics, with a vapor-liquid separation system and fluidized catalytic cracking zone to minimize coke formation and optimize product yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If heavy hydrocarbons are used as feedstock for steam pyrolysis, then the availability of feedstock increases and energy costs decrease, but coke formation increases and reactor operational duration decreases
Solution Approach 1:
The patent applies preliminary action by implementing a hydroprocessing step before steam pyrolysis. This pre-treatment process removes contaminants and reduces coke precursors from heavy hydrocarbon feedstocks, enabling longer reactor operational duration while maintaining the advantage of using abundant heavy feedstock.
Solution Approach 2:
The patent introduces an intermediary hydroprocessing unit between the feedstock supply and steam pyrolysis reactor. This intermediary process prepares the feedstock by reducing contaminant content and adjusting composition, thereby mediating between the desire to use heavy hydrocarbons and the need to prevent excessive coke formation.
2Quantity of substance
If heavy hydrocarbons are used as feedstock for steam pyrolysis, then feedstock availability increases, but olefin yields decrease and aromatic content increases
Solution Approach 1:
The patent applies parameter changes by modifying the feedstock composition through hydroprocessing. This process adjusts parameters such as contaminant content, paraffinicity, and aromatic content to optimize olefin yields while enabling the use of heavy hydrocarbon feedstocks.
Solution Approach 2:
The hydroprocessing step performs preliminary action on the feedstock to adjust its chemical composition before pyrolysis. This pre-treatment modifies the feedstock properties to achieve desired olefin yields and product distribution when using abundant heavy hydrocarbon feedstocks.
3Device complexity
If crude oil is processed directly without pre-treatment, then process complexity and energy costs decrease, but contaminant content increases and product quality decreases
Solution Approach 1:
The patent applies partial action by implementing a hydroprocessing step that selectively removes contaminants and adjusts composition without requiring complete refinement of the crude oil. This partial pre-treatment achieves sufficient product quality while avoiding excessive process complexity.
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 integrated process effectively reduces coke formation, increases olefin yields, and allows for the efficient production of petrochemicals like ethylene and propylene from crude oil feedstocks, enhancing operational stability and reducing energy costs by utilizing crude oil as a more abundant feedstock.
Implementation Method 1
Crude oil and hydrogen are charged to a hydroprocessing zone under conditions effective to produce an effluent having a reduced content of contaminants, an increased paraffinicity
Implementation Method 2
Hydroprocessed effluent is thermally cracked in the presence of steam in a steam pyrolysis zone to produce a mixed product stream
Implementation Method 3
Heavy components are catalytically cracked, which are derived from one or more of the hydroprocessed effluent, a heated stream within the steam pyrolysis zone, or the mixed product stream from steam cracking
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3C
AI summary
An integrated hydrotreating, steam pyrolysis and catalytic cracking process for the production of olefins and aromatic petrochemicals from a crude oil feedstock is provided. Crude oil and hydrogen are charged to a hydroprocessing zone under conditions effective to produce a hydroprocessed effluent, which is thermally cracked in the presence of steam in a steam pyrolysis zone to produce a mixed product stream. Heavy components are catalytically cracked, which are derived from one or more of the hydroprocessed effluent, a heated stream within the steam pyrolysis zone, or the mixed product stream catalytically cracking. Catalytically cracked products are produced, which are combined with the mixed product stream and the combined stream is separated, and olefins and aromatics are recovered as product streams.