Heat-Integrated Distillation for Pyrolysis Gasoline Separation

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Solution Overview

Problem

The separation of hydrocarbon streams between C6 and C7 in pyrolysis gasoline processing is energy-intensive, with the dehexanizer column being the largest energy consumer in the pygas section.

Innovation Solution

A system and method involving a first and second distillation column operating between lowest and highest pressures, with a heat exchanger arrangement where heat released from condensing a light stream is used to reboil a heavy stream, reducing the need for additional heating means and lowering overall energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional successive distillation columns are used to separate hydrocarbon streams, then separation between C6 and C7 fractions is achieved, but energy consumption increases significantly

Engineering Contradiction:
Improveseparation precisionVSAvoidenergy consumption
Core Design Contradiction:
Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies parameter changes by operating distillation columns at different pressure levels (first column at higher pressure, second column at lower pressure) to create temperature differences that enable heat integration. This pressure parameter modification allows the condenser of one column to provide heat to the reboiler of another column, reducing external energy consumption while maintaining separation precision between C6 and C7 fractions.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent merges the heat exchange functions by directly coupling the condenser of the first distillation column with the reboiler of the second distillation column. This merging allows heat released during condensation in the first column to be directly utilized for vaporization in the second column, eliminating the need for separate external heating and cooling systems and significantly reducing overall energy consumption.

Inventive Principle:
Principle #5Merging (Combining)

2Reliability

If multiple distillation columns operate independently, then separation function is maintained, but heat integration opportunities are lost

Engineering Contradiction:
Improveseparation functionVSAvoidheat energy
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The patent introduces heat exchangers as intermediary devices that facilitate heat transfer between the condenser and reboiler streams. These intermediaries enable efficient thermal coupling between distillation columns by transferring heat from the condensing vapor stream to the boiling liquid stream, preventing heat energy loss while maintaining the independence and reliability of each column's separation function.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent implements continuous heat integration where the heat released by condensing overhead vapors in one column continuously supplies the reboiler duties of another column. This continuous thermal interaction creates a cascading heat utilization pattern across multiple columns, ensuring that useful thermal energy is continuously transferred and utilized rather than being lost to the environment.

Inventive Principle:
Principle #20Continuity of useful action

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 saves approximately 50% of heat input compared to traditional methods, making the process more energy-efficient while maintaining the desired specifications for the separated streams.

Implementation Method 1

a heat exchanger comprising a first reboiler for reboiling a part of the first heavy stream to produce a first boiled heavy stream and a second condenser for condensing the second light stream to produce a second condensed light stream, wherein the first reboiler and the second condenser are arranged such that heat released from the second condenser is used as heat for the first reboiler

Methodology Applied
Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a first distillation column for producing a first light stream comprising C6− hydrocarbons and a first heavy stream comprising C7+ hydrocarbons

Methodology Applied
Scientific EffectDistillation: Distillation

Implementation Method 3

heat released from the second condenser for condensing the second light stream

Methodology Applied
Scientific EffectPhase change: Phase Change

Data Source

PatentUS10773183B2System and method for separating hydrocarbon stream
Publication Date: 2020.09.15 SABIC GLOBAL TECHNOLOGIES BV
  • US10773183B2 patent drawing
  • US10773183B2 patent drawing
  • US10773183B2 patent drawing

AI summary

The invention relates to a separation system for separating a feed stream comprising C6+ hydrocarbons, the system comprising: i) a first distillation column for producing a first light stream comprising C6− hydrocarbons and a first heavy stream comprising C7+ hydrocarbons, wherein the first distillation column is operated between a lowest pressure and a highest pressure, ii) a second distillation column for producing a second light stream comprising C6− hydrocarbons and a second heavy stream comprising C7+ hydrocarbons, wherein the second distillation column is operated between a lowest pressure and a highest pressure, wherein the lowest pressure of the second distillation column is higher than the highest pressure of the highest distillation column and iii) a heat exchanger comprising a first reboiler for reboiling a part of the first heavy stream to produce a first boiled heavy stream and a second condenser for condensing the second light stream to produce a second condensed light stream, wherein the first reboiler and the second condenser are arranged such that heat released from the second condenser is used as heat for the first reboiler.