Integrated Hydrocracking Process for Olefin Production
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Solution Overview
Problem
Integrated hydrocracking processes for producing olefinic and aromatic petrochemicals from crude oil face inefficiencies due to significant recycling of heavier steam cracking components, leading to increased equipment size and energy demand, and the downgrading of valuable crude oil to methane, resulting in unfavorable hydrogen balances and reduced carbon efficiency.
Innovation Solution
The process involves treating crude oil and residual liquid streams in hydrocracking zones with hydrogen to produce effluents that are separated into LPG and liquid phases, with specific streams being processed in steam crackers and dehydrogenation units to optimize the production of olefins and aromatics, reducing equipment size and energy demand by avoiding heavier component recycling and utilizing hydrogen efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heavier steam cracking components are recycled to increase olefin production, then olefin yield is improved, but equipment size and energy demand increase
Solution Approach 1:
The patent extracts and removes heavier steam cracking components (C5+) from the recycling loop through a dedicated separation unit. By taking out these heavy components before recycling, the system avoids the energy-intensive reheating and re-cracking of heavy materials while maintaining high olefin yields from the recycled lighter components (C1-C4).
Solution Approach 2:
The patent changes the composition parameter of the recycled stream by selectively removing heavier components. This parameter change transforms the recycle stream from a mixed composition containing C5+ to a refined composition with primarily C1-C4 components, which are more suitable for efficient steam cracking and olefin production.
2Productivity
If crude oil is hydrocracked to produce liquid hydrocarbon feed for steam cracking, then olefin production is improved, but carbon efficiency decreases due to methane formation
Solution Approach 1:
The patent recovers methane and other light gases (C1-C4) that would otherwise be discarded or used as fuel. Through the separation unit, these light components are captured and fed back to the steam cracking unit, converting them into valuable olefin products rather than losing them as methane, thereby improving carbon efficiency.
Solution Approach 2:
The patent converts the harmful effect of methane formation (which represents carbon loss and reduced efficiency) into a benefit by capturing and recycling the methane and light gases back to the steam cracking unit. What was previously a waste product or fuel source becomes a valuable feedstock for olefin production.
3Manufacturing precision
If hydrogen is added to crude oil in hydrocracking, then liquid hydrocarbon feed quality is improved, but hydrogen balance becomes unfavorable
Solution Approach 1:
The patent implements self-service by using the hydrogen-rich gases produced during hydrocracking (including unreacted hydrogen and hydrogen-containing light hydrocarbons) to meet the hydrogen requirements of the process. The separation unit captures these hydrogen-rich components and redirects them to maintain hydrogen balance, making the system self-sufficient for hydrogen needs.
Solution Approach 2:
The patent introduces feedback loops where the composition and quantity of gases from the hydrocracking unit are continuously monitored and fed back to adjust operating conditions. The separation and recycling of hydrogen-rich components creates a feedback mechanism that maintains favorable hydrogen balance while ensuring high liquid hydrocarbon feed quality.
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 significantly increases the conversion of crude oil to LPG, enhances carbon efficiency, and optimizes the production of olefinic and aromatic petrochemicals by controlling the severity of hydrocracking steps, resulting in decreased energy consumption and improved hydrogen utilization.
Implementation Method 1
treating the feedstock comprising crude oil and a residual liquid stream in a first hydrocracking zone in the presence of hydrogen under conditions effective to produce a first effluent having an increased hydrogen content
Implementation Method 2
a steam cracker unit to produce a mixed product stream, wherein one or more streams chosen from the group of said stream comprising ethane, said stream comprising C1-C2 and said stream comprising C2-minus is fed to said steam cracker unit
Implementation Method 3
at least one unit chosen from the group of a butanes dehydrogenation unit, a propane dehydrogenation unit, a combined propane-butanes dehydrogenation unit
Implementation Method 4
separating the first effluent into a LPG comprising stream and a liquid phase stream
Data Source
Figure 1
AI summary
The present invention relates to an integrated hydrocracking process for production of olefinic and aromatic petrochemicals from crude oil. An object of the present invention is to provide an integrated hydrocracking process for production of olefinic and aromatic petrochemicals from a hydrocarbon feedstock comprising crude oil wherein the portion of the crude oil converted to LPG is increased significantly.