Full Dense-Phase Catalytic Cracking Reactor for Heavy Oil
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current catalytic cracking technologies face challenges in efficiently converting heavy oil feedstocks into high-value light olefins and aromatics, leading to high yields of dry gas and coke, and struggle with product distribution and quality, especially when processing residue-blended heavy oils.
Innovation Solution
A process and system utilizing a reactor with a full dense-phase reaction zone, where the axial solid fraction of the catalyst is controlled between 0.1 and 0.2, allowing for improved catalyst-to-oil ratio and residence time, reducing dry gas and coke generation while increasing the yield of light olefins and aromatics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional steam cracking technology is used to produce light olefins from light feedstock, then light olefin production is achieved, but energy consumption is high and production cost is high
Solution Approach 1:
The patent changes the feedstock parameter from light feedstock to heavy feedstock oil, and changes the reaction conditions parameter by using catalytic cracking instead of steam cracking. This allows production of light olefins from heavier, more abundant feedstocks with lower energy consumption, directly resolving the contradiction between productivity and energy usage.
Solution Approach 2:
The patent replaces the thermal cracking mechanism of steam cracking with a catalytic cracking mechanism using zeolite catalysts. This substitution enables more efficient conversion of heavy feedstock into light olefins with lower energy requirements and better product distribution, addressing both energy consumption and productivity issues.
2Productivity
If traditional steam cracking technology is used, then light olefins are produced, but CO2 emission is high
Solution Approach 1:
By changing from steam cracking to catalytic cracking of heavy feedstock, the patent alters the chemical reaction pathway to produce more valuable products (light olefins and aromatics) with lower CO2 emissions, resolving the contradiction between productivity and harmful emissions.
3Productivity
If catalytic cracking technology is used to convert heavy oil into light olefins, then product distribution is improved, but dry gas and coke yield increases
Solution Approach 1:
The patent uses different zeolite catalysts with specific pore structures and acid distributions to control the local reaction characteristics. This allows selective promotion of reactions that produce desired light olefins while suppressing reactions that produce unwanted dry gas and coke, resolving the contradiction between productivity and substance loss.
Solution Approach 2:
The patent employs composite catalyst systems combining different zeolite types (e.g., ZSM-5, ZSM-11, ZSM-12) with complementary properties. This composite approach enables simultaneous optimization of light olefin production and minimization of dry gas and coke formation, addressing the contradiction between productivity and substance loss.
4Productivity
If heavy feedstock oil is processed to produce light olefins, then productivity is improved, but product quality and distribution control becomes difficult
Solution Approach 1:
The patent employs zeolite catalysts with specifically controlled pore sizes, shapes, and acid distributions to create local reaction zones that favor formation of desired light olefin products. This precise control over catalyst properties enables excellent product distribution control while maintaining high productivity from heavy 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
The process effectively enhances the conversion of heavy oil feedstocks into high-value light olefins and aromatics, improving product distribution and quality, and reduces dry gas and coke production, thereby addressing the limitations of existing technologies.
Implementation Method 1
contacting a hydrocarbon oil feedstock with a catalytic cracking catalyst for reaction in a reactor
Implementation Method 2
reactor comprising one or more fast fluidized reaction zones
Data Source
AI summary
A process for the catalytic cracking of hydrocarbon oils includes the step of contacting a hydrocarbon oil feedstock with a catalytic cracking catalyst in a reactor having one or more fast fluidized reaction zones for reaction. At least one of the fast fluidized reaction zones of the reactor is a full dense-phase reaction zone, and the axial solid fraction ε of the catalyst is controlled within a range of about 0.1 to about 0.2 throughout the full dense-phase reaction zone. When used for catalytic cracking of hydrocarbon oils, particularly heavy feedstock oils, the process, reactor and system show a high contact efficiency between oil and catalyst, a selectivity of the catalytic reaction, an effectively reduced yield of dry gas and coke, and an improved yield of high value-added products such as ethylene and propylene.