Integrated Hydrocarbon Upgrading via Solvent Deasphalting and Steam Enhanced Catalytic Cracking
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Solution Overview
Problem
The production of light olefins and BTX from crude oils is hindered by the presence of heavy residual hydrocarbons and impurities, which can deactivate catalysts and reduce conversion rates in refining processes.
Innovation Solution
An integrated process involving solvent deasphalting, delayed coking, hydrotreating, and steam enhanced catalytic cracking is employed to upgrade heavy hydrocarbon residuals and produce light olefins and BTX from crude oils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heavy residual hydrocarbons are directly processed in catalytic cracking, then the crude oil stream is fully utilized, but catalyst deactivation occurs and conversion rates decrease
Solution Approach 1:
The patent applies preliminary action by implementing solvent deasphalting and delayed coking processes before catalytic cracking. These preprocessing steps remove heavy residual hydrocarbons and impurities from the crude oil stream, preparing a cleaner feedstock that will not deactivate catalysts in subsequent cracking operations.
Solution Approach 2:
The patent segments the crude oil processing into distinct stages: solvent deasphalting to remove asphaltenes, delayed coking to convert heavy residuals, and finally catalytic cracking of the upgraded fractions. This segmentation allows each process to handle specific feedstock types optimally, preventing catalyst deactivation while maximizing light olefin and BTX production.
2Productivity
If crude oil is directly refined without upgrading heavy residuals, then the process is simpler, but impurities interfere with refining and reduce efficiency
Solution Approach 1:
The patent implements preliminary upgrading actions through solvent deasphalting and delayed coking to remove impurities before the main refining operations. This preliminary treatment prevents impurity interference in downstream processes, improving overall refining efficiency despite adding processing units.
Solution Approach 2:
The patent converts the harmful heavy residual hydrocarbons and impurities into beneficial products. Through delayed coking, these heavy residuals are transformed into petroleum coke (a valuable product) and upgraded oil fractions suitable for catalytic cracking, thereby turning potential catalyst poisons into useful materials.
3Reliability
If heavy residual hydrocarbons are removed before refining, then catalyst deactivation is prevented, but additional processing steps are required
Solution Approach 1:
The patent segments the processing into modular units: solvent deasphalting unit, delayed coker, and catalytic cracker. Each unit has a specific function in removing or converting heavy residuals, allowing catalyst protection while maintaining a structured, manageable process configuration.
Solution Approach 2:
The delayed coker serves multiple functions: it removes heavy residual hydrocarbons from the feedstock, produces petroleum coke as a saleable product, and generates upgraded oil fractions for further processing. This multi-functionality reduces the need for separate dedicated units, optimizing process complexity.
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 integrated process effectively upgrades heavy residual hydrocarbons, enhances catalyst efficiency, and increases the yield of light olefins and BTX, fully utilizing the crude oil stream.
Implementation Method 1
solvent deasphalting a hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons
Implementation Method 2
delayed coking the heavy residual hydrocarbons to form petroleum coke and a delayed coker product stream
Implementation Method 3
hydrotreating the delayed coker product stream and the deasphalted oil stream
Implementation Method 4
steam enhanced catalytically cracking the light C5+ hydrocarbon stream to form a light steam enhanced catalytically cracked product stream including olefins, benzene, toluene, xylene
Implementation Method 5
steam enhanced catalytically cracking
Data Source
AI summary
An integrated process for upgrading a hydrocarbon oil feed stream utilizing a delayed coker and steam enhanced catalytic cracker includes solvent deasphalting the hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons, the heavy residual hydrocarbons including at least asphaltenes; delayed coking the heavy residual hydrocarbons to form petroleum coke and a delayed coker product stream; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a light C5+ hydrocarbon stream, and a heavy C5+ hydrocarbon stream; steam enhanced catalytically cracking the light C5+ hydrocarbon stream to form a light steam enhanced catalytically cracked product stream including olefins, benzene, toluene, xylene, naphtha, or combinations thereof; and steam enhanced catalytically cracking the heavy C5+ hydrocarbon stream to form a heavy steam enhanced catalytically cracked product including olefins, benzene, toluene, xylene, naphtha, or combinations thereof.