Hydroprocessing Unit for BTX Aromatics from Crude Oil
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Solution Overview
Problem
Current processes for producing C6 to C8 aromatics and light gas olefins from crude oil are inefficient, as they utilize only a fraction of the crude oil and have low naphthenic content, leading to increased complexity and costs.
Innovation Solution
Incorporating a hydroprocessing unit upstream of the reforming unit to increase naphthenic content and reduce olefin content in the reformer feed, allowing for more efficient production of C6 to C8 aromatics and light gas olefins by separating hydrocarbon streams based on boiling points and recycling appropriate streams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single hydroprocessing unit is positioned upstream of the reforming unit, then the naphthene content in reformer feed increases and olefin content decreases, but the process complexity and equipment investment increase
Solution Approach 1:
The hydroprocessing unit is positioned upstream of the reforming unit to perform preliminary treatment of the crude oil feed. This preliminary action converts paraffins to naphthenes and removes olefins before the reforming process, ensuring optimal feed composition for aromatic production while simplifying the overall process design compared to multiple separate units
Solution Approach 2:
The hydroprocessing unit operates under specific parameters (temperature, pressure, catalyst composition) to achieve selective conversion of paraffins to naphthenes and removal of olefins. By controlling these parameters, the process optimizes naphthene content in the reformer feed while managing process complexity through parameter optimization rather than additional equipment
2Productivity
If multiple hydrocracking units are used to maximize aromatics production, then aromatics yield increases, but the process complexity and operational costs increase
Solution Approach 1:
The single hydroprocessing unit performs multiple functions: it acts as both a hydrocracking unit (converting paraffins to naphthenes) and a hydrotreating unit (removing olefins and impurities). This multi-functionality achieves high aromatics production yield equivalent to multiple separate units while reducing process complexity and equipment investment
Solution Approach 2:
The invention merges the functions of multiple hydrocracking units into a single integrated hydroprocessing unit. By combining these functions and operating the unit at optimized parameters, the process achieves maximum aromatics yield without the complexity and costs associated with multiple separate units
3Use of energy by moving object
If olefin content in reformer feed is high, then the reforming process becomes more exothermic and energy consumption increases, but removing olefins requires additional processing steps
Solution Approach 1:
The hydroprocessing unit performs preliminary removal of olefins from the crude oil feed before it enters the reforming unit. This preliminary action prevents excessive exothermicity in the reforming process, reducing energy consumption and avoiding the need for additional olefin removal steps downstream
Solution Approach 2:
The hydroprocessing unit extracts and removes olefins from the reformer feed through hydro treating reactions. By taking out the harmful olefin components before reforming, the process reduces unwanted exothermic reactions and energy consumption in the reforming unit while maintaining simple process architecture
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 enhances the efficiency of the reforming process, increases the yield of C6 to C8 aromatics, and reduces energy consumption by optimizing the use of crude oil and reducing olefin content, thereby improving overall process economics.
Implementation Method 1
a first stream is hydroprocessed to obtain a second stream. The first stream may include hydrocarbons from crude oil and/or pyrolysis oil
Implementation Method 2
separating the second stream to obtain a third stream including hydrocarbons having a boiling point less than 70° C., a fourth stream including hydrocarbons having a boiling point of 70° C. to 140° C., and a fifth stream including hydrocarbons having a boiling point greater than 140° C.
Data Source
AI summary
A process for producing C6 to C8 aromatics and optionally light gas olefins from crude oil and/or pyrolysis oil is disclosed. The process can include hydroprocessing a first stream containing hydrocarbons from the crude oil and/or pyrolysis oil to obtain a second stream containing saturated hydrocarbons having boiling point less than 350° C., separating the second stream to obtain a third stream containing hydrocarbons having boiling point less than 70° C., a fourth stream containing hydrocarbons having boiling point 70° C. to 140° C., and a fifth stream containing hydrocarbons having boiling point greater than 140° C., recycling at least a portion of the fifth stream to the hydroprocessing step, reforming the fourth stream to obtain a sixth stream containing C6 to C8 aromatics, and optionally cracking the third stream to obtain light gas olefins.