Flash Drum Vapor Liquid Separation Stripping Gas

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Solution Overview

Problem

Conventional steam cracking systems face challenges in efficiently processing hydrocarbon feedstocks containing high molecular weight, non-volatile components, which can lead to coke deposition and reduced efficiency due to poor separation of non-volatile and volatile hydrocarbons in the convection section of pyrolysis furnaces.

Innovation Solution

A vapor/liquid separation apparatus with a modified lower boot in the flash drum, featuring a gas-liquid contact surface and a stripping gas inlet, enhances the separation of non-volatile and volatile hydrocarbons by promoting additional vaporization of light hydrocarbons, thereby reducing coke formation and improving process economics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional pyrolysis furnaces process heavy feedstocks containing non-volatile components, then feedstock versatility is improved, but coke deposition increases and separation efficiency deteriorates

Engineering Contradiction:
Improvefeedstock versatilityVSAvoidcoke deposition
Core Design Contradiction:
Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies preliminary action by introducing a stripping gas (such as steam or nitrogen) into the flash drum before the vapor-liquid mixture enters the pyrolysis furnace. This pre-stripping operation removes non-volatile components from the liquid phase, preventing them from reaching the furnace where they would form coke. The stripping gas bubbles through the liquid in the flash drum, carrying volatile components into the vapor phase while leaving non-volatiles behind, thus preparing the feedstock in advance to avoid coke deposition problems.

Inventive Principle:
Principle #10Preliminary action

2Productivity

If heavy feedstocks are vaporized in the convection section, then cracking efficiency is improved, but non-volatile components lay down as coke and reduce system reliability

Engineering Contradiction:
Improvecracking efficiencyVSAvoidsystem reliability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent applies the taking out principle by extracting non-volatile components from the feedstock stream before it enters the pyrolysis furnace. The flash drum with stripping gas separation removes these harmful non-volatile components (which would otherwise form coke) from the vapor phase. The stripped vapor, now free of coke-forming contaminants, proceeds to the furnace for efficient cracking, while the non-volatiles are separated and removed, thus protecting the furnace and maintaining system reliability without sacrificing cracking efficiency.

Inventive Principle:
Principle #2Taking out (Extraction)

3Object-generated harmful factors

If flash drum separation is used to remove non-volatiles, then coke formation is reduced, but light hydrocarbons are lost in the bottoms and separation efficiency deteriorates

Engineering Contradiction:
Improvecoke formationVSAvoidlight hydrocarbon loss
Core Design Contradiction:
Object-generated harmful factorsVSLoss of substance

Solution Approach 1:

The patent applies the intermediary principle by using a stripping gas (steam or nitrogen) as a mediator in the flash drum separation process. The stripping gas bubbles through the liquid phase, selectively carrying volatile components including light hydrocarbons into the vapor phase while leaving non-volatile components in the liquid bottoms. This intermediary gas facilitates the separation process, ensuring that light hydrocarbons are not lost in the bottoms but are instead transferred to the vapor stream for subsequent cracking, thus preventing both coke formation and hydrocarbon loss simultaneously.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 apparatus significantly enhances non-volatile hydrocarbon removal efficiency, reducing the amount of light hydrocarbons in the flash drum bottoms and minimizing coke formation in the convection section, thereby improving the overall economics and efficiency of the steam cracking process.

Implementation Method 1

enhances the separation of non-volatile and volatile hydrocarbons by promoting additional vaporization of light hydrocarbons

Methodology Applied
Scientific EffectVaporization: Evaporation

Implementation Method 2

boot comprising sufficient gas-liquid contact surface (e.g., that provided by one or more sheds, baffles, and/or distillation trays) to provide at least a partial theoretical distillation stage

Methodology Applied
Scientific EffectGas-liquid mass transfer: Diffusion

Data Source

PatentUS7481871B2Vapor/liquid separation apparatus
Publication Date: 2009.01.27 EXXONMOBIL CHEMICAL PATENTS INC
  • US7481871B2 patent drawing
  • US7481871B2 patent drawing
  • US7481871B2 patent drawing

AI summary

A vapor/liquid separation apparatus for treating a flow of vapor/liquid mixtures of hydrocarbons and steam comprises a vertical drum with a side inlet to introduce hydrocarbon/steam mixtures, an overhead vapor outlet, and a lower section in communication with a cylindrical boot of less diameter than the drum, the boot comprising sufficient gas-liquid contact surface, e.g., that provided by one or more sheds, baffles and/or distillation trays, to provide at least a partial theoretical distillation stage, and a lower portion for receiving liquid from the drum, a lower outlet for removing the liquid, and an inlet for introducing a stripping gas, such as steam, hydrogen, light crackable hydrocarbon, and/or methane, below the distillation tray and preferably above the level of liquid in the boot.