Fluidized Bed Devolatilization for Residue Cracking
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Solution Overview
Problem
Existing refinery processes struggle to efficiently convert solid refinery residue into higher-valued products like liquid and gaseous hydrocarbons, while also being economically viable and environmentally friendly.
Innovation Solution
A process involving the introduction of solid refinery residue into a fluidized bed reactor, where it is heated to devolatilizing and thermal cracking temperatures to produce gaseous hydrocarbons and coke. The gaseous hydrocarbons are then subjected to catalytic hydroprocessing in the presence of molecular hydrogen to increase their value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If delayed coking or visbreaking processes are used to upgrade solid refinery residue, then conversion of residue to valuable products is achieved, but distillate yield is low and process cost is high
Solution Approach 1:
The patent changes the operational parameters by using a fluidized bed reactor that allows for controlled temperature profiles and residence times, enabling simultaneous devolatilization and cracking at optimized conditions that maximize distillate yield while maintaining high conversion efficiency
Solution Approach 2:
The patent segments the upgrading process into distinct stages: devolatilization to remove volatile components, thermal cracking to break down heavy molecules, and hydroprocessing to upgrade the cracked products. This segmentation allows each stage to be optimized independently, improving overall distillate yield
2Stability of the object's composition
If solvent de-asphalting is used as feed preparation, then feedstock quality for upgrading processes is improved, but additional process complexity and cost are introduced
Solution Approach 1:
The fluidized bed reactor is designed to perform multiple functions: it acts as both a devolatilization reactor and a cracking reactor, eliminating the need for separate feed preparation units and reducing overall process complexity while maintaining feedstock quality
Solution Approach 2:
The process uses the volatile components released during devolatilization as fuel for the cracking reactions, making the process self-sufficient in terms of energy requirements and eliminating the need for additional external energy input systems
3Quantity of substance
If ebullated bed or slurry hydrocracking is used to generate higher yields, then distillate production is improved, but process cost increases significantly
Solution Approach 1:
The patent replaces the complex mechanical mixing and catalyst management systems required in slurry hydrocracking with a fluidized bed system that uses fluid dynamics to achieve uniform catalyst contact and heat transfer, simplifying the overall process while maintaining high distillate yields
Solution Approach 2:
The patent introduces a fluidizing medium as an intermediary that facilitates heat and mass transfer between the solid catalyst particles and the liquid feedstock, enabling efficient cracking reactions without requiring complex mechanical mixing systems
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 process effectively upgrades solid refinery residue into high-value products such as C1-C3 hydrocarbons, liquefied petroleum gas, naphtha range hydrocarbons, and middle distillate range hydrocarbons, while also producing solid coke, thus enhancing the economic viability and environmental sustainability of the refining process.
Implementation Method 1
the refinery residue feedstock is heated to a devolatilizing and thermal cracking temperature in the fluidized bed reactor to produce a product stream comprising: gaseous hydrocarbons and solid coke
Implementation Method 2
The gaseous hydrocarbons may be subjected to catalytic hydroprocessing, in step c), in the presence of molecular hydrogen to increase the hydrogen to carbon ratio and lower the average molecular weight
Implementation Method 3
introducing the refinery residue feedstock into a fluidized bed reactor as a solid
Data Source
AI summary
Implementations of the disclosed subject matter provide a process for upgrading refinery residue feedstock. Step a) may include introducing the refinery residue feedstock into a fluidized bed reactor as a solid. In step b), the refinery residue feedstock may be heated to a devolatilizing and thermal cracking temperature in the fluidized bed reactor to produce a product stream comprising gaseous hydrocarbons and solid coke. The gaseous hydrocarbons may be subjected to catalytic hydroprocessing, in step c), in the presence of molecular hydrogen to increase the hydrogen to carbon ratio and lower the average molecular weight of the gaseous hydrocarbons. In step d), the gaseous hydrocarbons may be separated from the solid coke. In step e), the gaseous hydrocarbons from step d) may be subjected to further processing to produce at least one of: C1-C3 hydrocarbons, liquefied petroleum gas, naphtha range hydrocarbons, and middle distillate range hydrocarbons.