Integrated Hydrotreatment and Steam Cracking for Renewable Chemicals
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Solution Overview
Problem
Current methods for converting biomass into paraffinic hydrocarbons for steam cracking are energy intensive and technically challenging, leading to high fossil CO2 emissions and increased costs due to the use of fossil-based hydrogen production.
Innovation Solution
An integrated process that treats renewable organic materials through hydrotreatment, followed by thermal cracking and fractionation, where hydrogen is recycled and produced from renewable sources, including electrolysis using renewable electricity, and energy is generated from biogenic by-products, minimizing fossil CO2 emissions and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to convert biomass into paraffinic hydrocarbons, then the conversion can be achieved, but the process becomes energy intensive and produces high fossil CO2 emissions
Solution Approach 1:
The patent combines hydrotreatment, steam cracking, and fractionation units into an integrated system where process streams are interconnected. The hydrotreatment unit converts biomass to hydrocarbons, which then feed into the steam cracker, and the fractionation unit separates products. This merging of functions allows for internal recycling of hydrogen and energy, reducing external energy requirements and fossil CO2 emissions.
Solution Approach 2:
The integrated system is designed to be self-sufficient by recycling hydrogen from the steam cracking and fractionation units back to the hydrotreatment unit. Additionally, the system uses its own process energy and by-products to sustain operation, reducing dependence on external fossil fuel inputs and thereby lowering energy intensity and carbon emissions.
2Quantity of substance
If fossil-based hydrogen production is used in the hydrotreatment process, then hydrogen can be supplied, but costs increase and fossil CO2 emissions rise
Solution Approach 1:
The system implements a feedback loop where hydrogen produced during steam cracking and fractionation is recycled back to the hydrotreatment unit. This feedback mechanism ensures that hydrogen generated within the system is reused, reducing the need for external fossil-based hydrogen production and thereby lowering both costs and fossil CO2 emissions.
Solution Approach 2:
Instead of discarding hydrogen as a by-product or requiring continuous external supply, the system recovers and reuses hydrogen internally. The steam cracking and fractionation units generate hydrogen that is captured and fed back to the hydrotreatment unit, transforming a potential waste product into a valuable resource and eliminating the need for fossil-based hydrogen production.
3Object-generated harmful factors
If an integrated process with hydrogen recycling is implemented, then CO2 emissions and costs are reduced, but device complexity increases
Solution Approach 1:
The integrated system is designed with multi-functional units where each component serves multiple purposes. For example, the steam cracking unit not only cracks hydrocarbons but also generates hydrogen for recycling. The fractionation unit separates products while also managing hydrogen recovery. This universality reduces the need for separate dedicated systems, thereby managing complexity while achieving emission reductions.
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 reduces CO2 emissions and costs by utilizing renewable energy and hydrogen, achieving a zero or negative fossil carbon footprint for the production of high-value chemicals like ethylene, propylene, and BTX aromatics.
Implementation Method 1
contacting it with hydrogen (hydrotreatment process)... Feeding the pre-treated organic material from the at least one pre-treatment unit to at least one hydrotreatment unit for providing gas-oil like hydrocarbons from the pre-treated organic material in the presence of hydrogen and a catalyst
Implementation Method 2
Feeding the gas-oil like hydrocarbons from the at least one hydrotreatment unit into at least one steam cracker furnace unit for thermal cracking for providing a cracked product mixture
Implementation Method 3
Feeding the cracked product mixture into at least one steam cracker fractionation unit for separating the cracked product mixture into high value chemicals
Implementation Method 4
at least another part of the hydrogen required for hydrotreatment of the pre-treated organic material in the hydrotreatment unit is provided by at least one electrolyser using water released during the hydrotreatment of the organic material
Data Source
AI summary
Provided is an integrated process for obtaining chemicals from renewable organic material by hydrotreatment including the steps of feeding the renewable organic material into at least one pre-treatment unit for removing any material not suitable as feedstock for subsequent hydrotreatment, feeding the pre-treated organic material from the at least one pre-treatment unit to at least one hydrotreatment unit for providing gas-oil like hydrocarbons from the pre-treated organic material in the presence of hydrogen and a catalyst, feeding the gas-oil like hydrocarbons from the at least one hydrotreatment unit into at least one steam cracker furnace unit for thermal cracking for providing a cracked product mixture; and feeding the cracked product mixture into at least one steam cracker fractionation unit for separating the cracked product mixture into high value chemicals in particular ethylene, propylene, butadiene and BTX aromatics, hydrogen, fuel gas and fuel oil.