Heavy Hydrocarbon Upgrading via Ring-Opening and Hydrocracking
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Solution Overview
Problem
Conventional methods for upgrading heavy hydrocarbon feedstocks to petrochemicals, such as steam cracking and hydrocracking, face inefficiencies in producing high-value aromatics and light olefins, with significant capital costs and hydrogen consumption, and are unsuitable for processing heavier crude oil cuts due to high capital costs and heat management issues.
Innovation Solution
A process combining ring-opening reactions with hydrocracking and steam cracking units, including pre-treatment steps like hydrodealkylation and aromatics extraction, to enhance the yield of aromatics and light olefins, with integrated hydrogen loops for efficient hydrogen use and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional steam cracking and hydrocracking methods are used to upgrade heavy hydrocarbon feedstocks, then light olefins and aromatics can be produced, but capital costs and hydrogen consumption are excessively high
Solution Approach 1:
The process segments the conversion of heavy hydrocarbons into distinct stages: (1) hydrodealkylation to remove alkyl groups and form aromatics, (2) ring-opening reactions to convert aromatics to cycloalkanes and then to olefins, and (3) selective cracking to produce light olefins. This segmentation allows each stage to be optimized independently, reducing overall hydrogen consumption while maintaining high yields of desired products.
Solution Approach 2:
The process performs preliminary hydrodealkylation and aromatics extraction before the main cracking operations. By pre-concentrating aromatic compounds and removing alkyl groups in advance, the subsequent ring-opening and cracking stages require less hydrogen and operate more efficiently, thereby reducing total hydrogen consumption while improving aromatics and light olefin yields.
2Adaptability or versatility
If conventional methods process heavier crude oil cuts, then more feedstock can be utilized, but heat management issues and high capital costs arise
Solution Approach 1:
The process employs parameter changes by conducting reactions at moderate temperatures and pressures rather than the extreme conditions required by conventional steam cracking. The hydrodealkylation and ring-opening reactions proceed efficiently at lower temperatures, enabling the processing of heavier crude oil cuts without the heat management problems that plague conventional high-temperature processes.
Solution Approach 2:
The process introduces aromatic compounds as intermediaries in the conversion of heavy hydrocarbons to light olefins. Heavy feeds are first converted to aromatics via hydrodealkylation, then aromatics are converted to cycloalkanes and subsequently to olefins through ring-opening reactions. This intermediary pathway allows heavy feeds to be processed under milder conditions, improving adaptability while avoiding heat management issues.
3Productivity
If conventional hydrocracking is used to convert heavy hydrocarbons, then fuel products are produced, but the process is unsuitable for petrochemical production due to high capital costs
Solution Approach 1:
The process inverts the conventional approach by not directly cracking heavy hydrocarbons to fuels, but first converting them to aromatic compounds through hydrodealkylation, then converting aromatics to olefins through ring-opening reactions. This inverted pathway prioritizes petrochemical feedstock production over fuel production, enabling high-value petrochemical manufacturing with reduced capital costs compared to conventional hydrocracking designed for fuel production.
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 increases the yield of aromatics and light olefins, reduces capital costs by processing heavier feeds efficiently, and improves hydrogen integration, making it economically viable to produce high-value petrochemicals from heavy hydrocarbon feedstocks.
Implementation Method 1
converting cyclic hydrocarbons to linear hydrocarbons
Implementation Method 2
hydrocracking unit, separating reaction products into an overhead gas stream comprising light boiling hydrocarbons and a BTX comprising bottom stream
Implementation Method 3
separation unit for producing a gaseous stream comprising light boiling hydrocarbons, a liquid stream comprising naphtha boiling range hydrocarbons and a liquid stream comprising diesel boiling range hydrocarbons
Implementation Method 4
steam cracking unit to produce light olefins
Data Source
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AI summary
The present invention relates to a process for upgrading refinery heavy hydrocarbons to petrochemicals, comprising the following steps of: (a) feeding a hydrocarbon feedstock to a ring opening reaction area; (b) feeding the effluent from (a) to a separation unit for producing a gaseous stream comprising light boiling hydrocarbons, a liquid stream comprising naphtha boiling range hydrocarbons and a liquid stream comprising diesel boiling range hydrocarbons; (c) feeding said liquid stream comprising naphtha boiling range hydrocarbons to a hydrocracking unit.