Integrated Hydrocarbon Upgrading via Solvent Deasphalting and Delayed Coking
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Solution Overview
Problem
The production of light olefins such as ethylene, propylene, and butylene is challenging due to the presence of heavy residual hydrocarbons and impurities in crude oils, which can deactivate catalysts and reduce conversion rates in refining processes like hydrocracking, steam cracking, and fluid catalytic cracking.
Innovation Solution
An integrated process and system that includes solvent deasphalting, delayed coking, hydrotreating, dehydrogenation, and steam enhanced catalytic cracking to upgrade heavy hydrocarbon residuals and produce light olefins and BTX (benzene, toluene, xylene) from crude oils, thereby utilizing the entire crude oil stream effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heavy residual hydrocarbons and impurities are directly processed in refining processes like hydrocracking, steam cracking, and fluid catalytic cracking, then the production of light olefins can proceed, 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 the main refining operations. These preprocessing steps remove heavy residual hydrocarbons and impurities from the crude oil feedstock, preventing catalyst deactivation in subsequent hydrocracking, steam cracking, and fluid catalytic cracking units while maintaining high light olefin production
2Productivity
If crude oil is directly refined without upgrading heavy residuals, then the process is simpler, but impurities interfere with refining processes and reduce efficiency
Solution Approach 1:
The patent applies segmentation by dividing the crude oil refining process into distinct sequential stages: solvent deasphalting to separate asphaltenes, delayed coking to convert heavy residuals, followed by main refining processes. This segmentation isolates impurity removal functions from the main refining operations, improving overall efficiency while organizing complexity into manageable modular units
3Productivity
If catalysts are used in refining processes with heavy residual hydrocarbons, then light olefin conversion can occur, but coke buildup deactivates catalysts increasing recycling or replacement costs
Solution Approach 1:
The patent removes coke precursors through delayed coking before the catalytic cracking process. This preliminary removal of heavy residual hydrocarbons prevents coke buildup on catalysts during subsequent fluid catalytic cracking operations, maintaining catalyst activity and reducing the frequency and cost of catalyst recycling or replacement while preserving high light olefin conversion rates
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, removes impurities, and enhances the production of light olefins and BTX, improving the efficiency and yield of refining processes while minimizing catalyst deactivation and operational costs.
Implementation Method 1
solvent deasphalting a hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons, the heavy residual hydrocarbons including at least asphaltenes
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 to form a C3-C4 hydrocarbon stream, a light C5+ hydrocarbon stream, and a heavy C5+ hydrocarbon stream
Implementation Method 4
dehydrogenating the C3-C4 hydrocarbon stream to form propylene and butylene
Implementation Method 5
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
Implementation Method 6
steam enhanced catalytically cracking
Data Source
AI summary
An integrated process for upgrading a hydrocarbon oil feed stream includes solvent deasphalting the hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons, 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 C3-C4 hydrocarbon stream, a light C5+ hydrocarbon stream, and a heavy C5+ hydrocarbon stream; dehydrogenating the C3-C4 hydrocarbon stream to form propylene and butylene; 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.