FCC Slurry Recovery via Dual-Stream Temperature Segmentation

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Solution Overview

Problem

Conventional methods for processing fluid catalytic cracking (FCC) slurry oil face challenges with coke accumulation and fouling due to sub-optimal temperature conditions, limiting the separation of lighter hydrocarbons like light cycle oil and heavy cycle oil.

Innovation Solution

The method involves drawing two FCC slurry streams from different locations in the fractionation column at distinct temperatures, with the first stream being cooled and recycled to reduce fouling, and the second stream being sent to a separation zone at a higher temperature for efficient hydrocarbon recovery using vacuum distillation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If MCB is cooled and recycled as quench liquid to reduce coke accumulation and fouling, then fouling is reduced, but separation of lighter hydrocarbons is limited due to sub-optimal temperature

Engineering Contradiction:

Improvefouling reductionVSAvoidhydrocarbon separation efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The MCB stream is divided into two separate streams drawn from different locations in the fractionation column. The first stream (quenched, cooler) is recycled to reduce fouling, while the second stream (elevated temperature) is sent to the separation zone for efficient hydrocarbon recovery. This segmentation allows each stream to serve its optimal function without compromise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different temperature conditions are applied to different portions of the MCB stream based on their destination function. The quench stream receives cooling treatment suitable for fouling reduction, while the separation stream maintains elevated temperature optimal for hydrocarbon separation. Each local portion of the system receives the quality (temperature) it needs for its specific purpose.

Inventive Principle:

Principle #3Local quality

2Object-generated harmful factors

If MCB temperature is reduced by quenching to prevent coke accumulation, then coke accumulation is reduced, but separation of lighter hydrocarbons becomes less efficient

Engineering Contradiction:

Improvecoke accumulationVSAvoidlight hydrocarbon separation

Core Design Contradiction:

Object-generated harmful factorsVSProductivity

Solution Approach 1:

The MCB stream is segmented into two streams from different column locations. The first stream is cooled for quenching to prevent coke accumulation, while the second stream maintains elevated temperature for efficient light hydrocarbon separation in the separation zone.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different temperature parameters are applied to different MCB streams based on their function. The quench stream uses lower temperature to suppress coking, while the separation stream uses higher temperature to optimize hydrocarbon separation efficiency.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If single MCB stream is used for both quenching and separation, then system complexity is reduced, but both functions cannot be optimized simultaneously

Engineering Contradiction:

Improvesystem complexityVSAvoidprocess optimization

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The single MCB stream is segmented into two separate streams drawn from different locations in the fractionation column. This segmentation enables independent optimization of quenching and separation functions while maintaining manageable system complexity through a straightforward dual-stream configuration.

Inventive Principle:

Principle #1Segmentation

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 approach allows for effective hydrocarbon recovery from FCC slurry at elevated temperatures, reducing fouling and enhancing separation efficiency while minimizing coking issues, thereby improving the overall processing reliability and product yield.

Implementation Method 1

separating the FCC effluent with a fractionation column to generate a product stream and a FCC slurry

Methodology Applied

Scientific EffectFractionation: Fractionation

Implementation Method 2

separating a hydrocarbon from the second FCC slurry stream

Methodology Applied

Scientific EffectVacuum distillation: Vacuum Distillation

Implementation Method 3

separating a hydrocarbon from the second FCC slurry stream with a vacuum distillation column

Methodology Applied

Scientific EffectDistillation: Distillation

Data Source

PatentUS10640717B2Methods and systems for recovery of hydrocarbons from fluid catalytic cracking slurry

Publication Date: 2020.05.05 UOP LLC

AI summary

Methods and systems for recovering a hydrocarbon from fluid catalytic cracking (“FCC”) slurry and for separating a FCC slurry stream from a FCC effluent are provided. An exemplary hydrocarbon recovery method comprises the steps of: contacting a feed with a catalyst in a FCC reactor under conditions suitable to crack one or more hydrocarbons and generate a FCC effluent; separating the FCC effluent with a fractionation column to generate a product stream and a FCC slurry that collects in a lower portion of the fractionation column; drawing a first FCC slurry stream at a first temperature from a first location in the fractionation column; drawing a second FCC slurry stream at a second temperature from a second location in the fractionation column, and separating a hydrocarbon from the second FCC slurry stream, wherein the second temperature is higher than the first temperature.