Integrated FCC and Coker Upgrading for Low-CO2 Olefin Production
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Solution Overview
Problem
Conventional methods for processing crude oil and refined feedstocks like vacuum residue and fuel oil are costly, energy-intensive, and have a high CO2 footprint, failing to efficiently produce valuable light olefins and other petrochemicals.
Innovation Solution
An integrated method and system that includes cracking crude oil in a downflow reaction zone of a fluid catalytic cracking unit, processing refined feedstock in a coker, and upgrading portions of the FCC and coker products in an upgrading unit, while capturing CO2 as solid coke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional separate processing methods are used for crude oil and refined feedstocks, then processing flexibility is maintained, but capital expenditures and operational expenditures increase
Solution Approach 1:
The patent combines separate processing systems for crude oil and refined feedstocks into a single integrated processing system. The crude oil processing unit and refined feedstock processing unit are merged to share common infrastructure including separation units, upgrading units, and product distribution systems, thereby reducing capital expenditures while maintaining processing flexibility through modular design
2Object-affected harmful factors
If conventional processing methods are used for vacuum residue and fuel oil, then processing simplicity is maintained, but CO2 footprint increases
Solution Approach 1:
The patent converts the harmful CO2 emissions from processing vacuum residue and fuel oil into useful chemical products. Through catalytic cracking and upgrading processes, carbon-containing feedstocks are transformed into valuable light olefins, aromatics, and other petrochemicals, thereby reducing the CO2 footprint while simultaneously improving processing efficiency and product value
3Productivity
If conventional cracking processes are used, then processing simplicity is maintained, but light olefin production efficiency decreases
Solution Approach 1:
The patent employs advanced cracking processes with controlled parameters including temperature, pressure, and catalyst selection to optimize light olefin production. By precisely controlling cracking conditions and using selective catalysts, the system maximizes light olefin yield from various feedstocks while managing process complexity through automated parameter control and monitoring
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
Reduces capital and operational expenditures and decreases the CO2 footprint by converting crude oil and refined feedstocks into higher-value products, including light olefins and petrochemicals.
Implementation Method 1
cracking the crude oil feedstock in a downflow reaction zone of a fluid catalytic cracking unit
Implementation Method 2
processing the refined feedstock in a coker to produce a first coker product and a second coker product comprising solid coke
Data Source
AI summary
A method of processing a crude oil feedstock and a refined feedstock comprising vacuum residue and/or fuel oil, the method may comprise: cracking the crude oil feedstock in a downflow reaction zone of a fluid catalytic cracking unit to produce a first FCC product; processing the refined feedstock in a coker to produce a first coker product and a second coker product comprising solid coke; and processing at least a portion of the first FCC product and at least a portion of the first coker product in an upgrading unit to produce an upgraded product stream.