Coupling Reaction Apparatus for Heavy Oil Pyrolysis
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Solution Overview
Problem
Current heavy oil processing technologies face challenges such as catalyst deactivation, high hydrogen consumption, and inefficient energy use due to the low H/C ratio and high sulfur content of inferior heavy oil, leading to complex and costly processing methods like delayed coking, which results in low liquid yield and waste of heavy oil resources.
Innovation Solution
A coupling reaction apparatus that integrates heavy oil cracking and gasification processes, where a cracking section above a gasification section allows for the efficient conversion of coke particles into synthesis gas, which is then reused to enhance the cracking reaction, reducing energy consumption and increasing the yield of high-quality oil-gas products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If delayed coking technology is used to process inferior heavy oil, then the processing capability is improved, but the liquid yield decreases and low-value petroleum coke is produced
Solution Approach 1:
The patent combines cracking and gasification processes into a single coupling reaction apparatus, where the cracking section produces coke particles that are directly gasified in the gasification section. This integration allows simultaneous production of high-quality oil-gas products and synthesis gas, eliminating the need for separate delayed coking units and improving overall liquid yield while maintaining processing capability.
2Productivity
If delayed coking technology is used to process inferior heavy oil, then the processing capability is improved, but low-value petroleum coke is produced
Solution Approach 1:
The patent converts the harmful coke particles that would normally be discarded as low-value petroleum coke into a valuable resource by gasifying them in the gasification section. The coke particles serve as feedstock for producing high-quality synthesis gas, transforming a waste product into a useful chemical feedstock for further processing or energy generation.
3Productivity
If catalytic cracking or catalytic hydrogenation is used to process inferior heavy oil, then the processing capability is improved, but catalyst deactivation occurs
Solution Approach 1:
The patent extracts the harmful functions from the catalytic process by removing the catalyst entirely. Instead of using catalytic cracking or hydrogenation that suffer from catalyst deactivation, the invention employs thermal cracking in the cracking section followed by gasification in the gasification section, eliminating catalyst-related reliability issues while maintaining processing capability.
4Productivity
If catalytic cracking or catalytic hydrogenation is used to process inferior heavy oil, then the processing capability is improved, but hydrogen consumption increases
Solution Approach 1:
The system produces its own hydrogen needs internally through the gasification process. The gasification section generates synthesis gas containing hydrogen from the coke particles, which can be directly used for hydrogenation processes or further processed to meet the refinery's hydrogen requirements, making the system self-sufficient and eliminating external hydrogen consumption.
5Productivity
If direct gasification of inferior heavy oil is used, then the conversion to small molecules is improved, but oil-gas molecules and hydrogen elements are not fully utilized
Solution Approach 1:
The patent segments the conversion process into two distinct stages: first, thermal cracking converts heavy oil into lighter oil-gas products and coke particles; second, the coke particles are gasified into synthesis gas. This segmentation allows full utilization of all carbon-containing materials, ensuring that oil-gas molecules and hydrogen elements are completely converted into valuable products without waste.
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 achieves higher yields and quality of oil-gas products while reducing energy consumption and minimizing the production of low-value petroleum coke, by enabling material and energy exchange between the cracking and gasification reactions, thus improving the technical economy and efficiency of the process.
Implementation Method 1
a cracking section (1) ... configured to convert a heavy oil into an oil-gas and coke particles
Implementation Method 2
a gasification section (2) ... configured to convert the coke particles into a synthesis gas
Implementation Method 3
the synthesis gas can not only provide heat for the cracking reaction
Data Source
AI summary
A coupling reaction apparatus for heavy oil cracking-gasification, including a cracking section and a gasification section communicated with each other, and the cracking section is located above the gasification section; the cracking section is provided with a heavy oil raw material inlet and a fluidizing gas inlet, and an upper part of the cracking section is provided with an oil-gas outlet; and the gasification section is provided with a gasification agent inlet.