Integrated Hydroprocessing of FCC Naphtha and Pyrolysis Gasoline

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Solution Overview

Problem

Current petrochemical processes are limited in simultaneously producing olefin and aromatic rich streams due to the need to hydro-process different feedstocks separately, leading to lower aromatic and olefin contents and higher operational costs.

Innovation Solution

An integrated process that combines and hydro-processes a pyrolysis gasoline stream and a full range cracked naphtha stream to produce a plurality of olefin and aromatic hydrocarbon streams, involving catalytic cracking, steam cracking, mixing, and hydro-processing to enhance olefin and aromatic production while minimizing operational costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If separate hydro-processing units are used for FCC naphtha and pyrolysis gasoline, then each feedstock can be processed independently, but operational costs increase and aromatic/olefin production efficiency decreases

Engineering Contradiction:

Improveolefin and aromatic production efficiencyVSAvoidnumber of hydro-processing units

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines two separate hydro-processing streams (FCC naphtha and pyrolysis gasoline) into a single integrated hydro-processing unit. The mixed feedstock containing both FCC naphtha and pyrolysis gasoline is processed together through one hydro-processing unit, eliminating the need for two separate units while maintaining effective processing of both feedstocks and reducing operational costs.

Inventive Principle:

Principle #5Merging (Combining)

2Device complexity

If FCC naphtha and pyrolysis gasoline are mixed before hydro-processing, then operational costs are reduced, but the hydro-processing unit must handle more complex mixed feedstock

Engineering Contradiction:

Improvenumber of hydro-processing unitsVSAvoidfeedstock processing complexity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The hydro-processing unit is designed with multi-functionality to handle both FCC naphtha and pyrolysis gasoline simultaneously. The catalyst system and processing conditions are optimized to effectively process the mixed feedstock containing different hydrocarbon types, making the single unit versatile enough to perform the functions previously requiring two separate units.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If separate hydro-processing is used, then each stream maintains its original composition, but aromatic and olefin contents in the combined stream are reduced

Engineering Contradiction:

Improvefeedstock composition integrityVSAvoidaromatic and olefin content

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The patent employs parameter changes in the hydro-processing conditions, including temperature, pressure, and catalyst composition, to optimize the processing of mixed feedstock. These parameter adjustments enable the single hydro-processing unit to effectively convert the mixed FCC naphtha and pyrolysis gasoline into products with enhanced aromatic and olefin contents, overcoming the limitations of separate processing.

Inventive Principle:

Principle #35Parameter changes

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 increases olefin and aromatic production with minimal loss, achieving up to 99% hydrogenation of diolefins and 98% saturation of mono-olefins, resulting in a hydro-processed stream with reduced sulfur content and increased aromatic content, thereby improving product yield and reducing operational costs.

Implementation Method 1

catalytically cracking a first hydrocarbon feedstock to form a full range cracked naphtha stream and a first light olefins stream

Methodology Applied

Scientific EffectCatalytic cracking: Catalysis

Implementation Method 2

steam cracking a second hydrocarbon feedstock to form a heavy pyrolysis oil stream, a pyrolysis gasoline stream, and a second light olefins stream

Methodology Applied

Scientific EffectSteam cracking: Pyrolysis

Implementation Method 3

hydrogenating the combined stream with a first hydro-processing catalyst to convert one or more diolefins present in the combined stream into one or more mono-olefins

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Implementation Method 4

saturating the hydrogenated combined stream with a second hydro-processing catalyst to convert mono-olefins into paraffins

Methodology Applied

Scientific EffectSaturation: Hydrogenation

Implementation Method 5

removing one or more components comprising nitrogen, sulfur, metals and/or any combination thereof from the combined stream

Methodology Applied

Scientific EffectHydro-desulfurization: Hydrolysis

Data Source

PatentUS10710942B2Method of co-processing fluidized catalytic cracking naphtha and pyrolysis gasoline

Publication Date: 2020.07.14 SABIC GLOBAL TECHNOLOGIES BV

AI summary

An integrated process for forming a combined feedstock stream comprising catalytically cracking a first hydrocarbon feedstock to form a full range cracked full naphtha stream and a first light olefins stream, steam cracking a second hydrocarbon feedstock to form a pyrolysis gasoline stream and a second light olefins stream mixing at least a portion of each of the full range cracked naphtha stream and the pyrolysis gasoline stream to form a combined stream, hydro-processing the combined stream to form a hydro-processed combined stream splitting the hydro-processed combined stream into a C5/C6 stream, and a first aromatic rich stream, splitting the first aromatic rich stream into a second aromatic rich stream and a heavy oil stream.