Integrated Hydrotreating and Steam Pyrolysis for Crude Oil Conversion
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Solution Overview
Problem
Current processes for producing olefinic and aromatic petrochemicals from crude oil are limited by the availability and cost of feedstocks, and require energy-intensive steps, with existing integrated hydrotreating and steam pyrolysis processes not fully optimizing the conversion of crude oil fractions.
Innovation Solution
An integrated hydrotreating and steam pyrolysis process that separates crude oil into light and heavy components, subjects the heavy components to hydrotreating, followed by steam pyrolysis, with hydrogen recycling and caustic treatment to enhance product yield and purity, and includes resid hydrocracking and slurry hydroprocessing to maximize the production of valuable hydrocarbon streams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional steam pyrolysis is used with limited feedstocks, then olefinic and aromatic petrochemicals can be produced, but the process requires costly and energy-intensive steps
Solution Approach 1:
The patent combines hydrotreating and steam pyrolysis into an integrated process where the hydrotreating unit prepares crude oil fractions by removing contaminants, and the steam pyrolysis unit converts these treated fractions into olefins and aromatics. This merging eliminates the need for separate, energy-intensive feedstock preparation steps and allows direct processing of crude oil fractions.
Solution Approach 2:
The hydrotreating unit performs preliminary processing of crude oil fractions before they enter the steam pyrolysis unit. By removing sulfur, nitrogen, and metal contaminants in advance, the process avoids energy-intensive purification steps that would be required after pyrolysis, and enables more efficient conversion to desired products.
2Productivity
If integrated hydrotreating and steam pyrolysis processes are implemented, then conversion of crude oil fractions can be improved, but the process complexity increases
Solution Approach 1:
The integrated process is divided into distinct functional units: a hydrotreating unit with catalyst beds for removing contaminants, and a steam pyrolysis unit for converting treated fractions to olefins and aromatics. This segmentation allows each unit to be optimized independently while maintaining overall process efficiency and managing complexity through modular design.
Solution Approach 2:
The hydrotreating unit serves multiple functions: removing sulfur, nitrogen, and metal contaminants, and preparing the crude oil fractions for optimal pyrolysis conversion. The steam pyrolysis unit then converts these pre-treated fractions into valuable petrochemical products. This multi-functionality reduces the need for additional separate processing units.
3Productivity
If feedstocks for steam pyrolysis are obtained from petroleum gases and distillates, then olefinic and aromatic petrochemicals can be produced, but the availability of these feedstocks is limited
Solution Approach 1:
The process uses crude oil fractions directly as feedstock for the integrated hydrotreating and steam pyrolysis units, eliminating dependence on externally sourced petroleum gases and distillates. The hydrotreating unit processes the crude oil fractions in place, converting them into suitable feedstock for pyrolysis, thereby making the system self-sufficient and expanding feedstock availability.
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 process increases the yield of olefins and aromatics, reduces contaminants, and improves the API gravity of products, making the production more efficient and cost-effective by optimizing the conversion of crude oil fractions and recycling hydrogen, thereby reducing energy consumption and operational costs.
Implementation Method 1
exposing a combined feedstock comprising a heavy oil feed component and a solvent component to a hydroprocessing catalyst to form a hydro processed effluent
Implementation Method 2
exposing a combined feedstock comprising a heavy oil feed component and a solvent component to a hydroprocessing catalyst
Implementation Method 3
thermal cracking, or steam pyrolysis, is a major type of process for forming these materials, typically in the presence of steam, and in the absence of oxygen
Implementation Method 4
thermal cracking, or steam pyrolysis, is a major type of process for forming these materials
Implementation Method 5
charging the hydroprocessed effluent and steam to a convection section of a steam pyrolysis zone; heating the mixture from step (c1)
Implementation Method 6
passing it to a vapor-liquid separation section
Implementation Method 7
compressing the thermally cracked mixed product stream with plural compression stages
Implementation Method 8
subjecting the compressed thermally cracked mixed product stream to caustic treatment to produce a thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide
Implementation Method 9
dehydrating the compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide
Data Source
AI summary
An integrated hydrotreating and steam pyrolysis process for the direct processing of a crude oil to produce olefinic and aromatic petrochemicals by separating the crude oil into light components and heavy components.