Integrated Deasphalting and Coker-Cracker Refining for Olefins and BTX
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Solution Overview
Problem
Existing refining processes face challenges in producing light olefins and BTX from crude oils due to the presence of heavy residual hydrocarbons and impurities, which lead to catalyst deactivation and reduced conversion rates.
Innovation Solution
An integrated process involving solvent deasphalting, delayed coking, hydrotreating, and steam-enhanced catalytic cracking to upgrade heavy hydrocarbons, followed by processing in an aromatics complex to produce light olefins and BTX.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If crude oil stream is directly processed in refining processes, then production of light olefins and BTX is achieved, but heavy residual hydrocarbons and impurities cause catalyst deactivation and reduced conversion rates
Solution Approach 1:
The patent applies preliminary action by implementing a deasphalting unit before the refining process to remove heavy residual hydrocarbons and impurities from the crude oil stream. This preliminary treatment prevents catalyst deactivation and maintains high conversion rates throughout the subsequent refining operations, thereby resolving the contradiction between productivity and reliability.
2Adaptability or versatility
If heavy residual hydrocarbons are present in the crude oil stream, then the crude oil can be processed, but they generate petroleum coke on catalysts leading to deactivation
Solution Approach 1:
The patent applies the extraction principle by using a deasphalting unit to selectively remove heavy residual hydrocarbons (asphaltenes) from the crude oil stream before they enter the refining process. This extraction prevents the formation of petroleum coke on catalysts, maintaining catalyst activity while still allowing processing of the crude oil stream.
3Productivity
If impurities such as nitrogen are present in the crude oil stream, then the crude oil can be refined, but they cause gum formation, catalyst inhibition, and corrosion
Solution Approach 1:
The patent applies preliminary action by implementing a deasphalting unit that removes impurities including nitrogen-containing compounds from the crude oil stream before refining. This preliminary removal prevents gum formation, catalyst inhibition, and corrosion during the refining process, thereby maintaining high productivity.
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
Enhances the production of light olefins and BTX by effectively removing impurities and upgrading heavy hydrocarbons, improving catalyst efficiency and overall refining process performance.
Implementation Method 1
solvent deasphalting a hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons
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
Implementation Method 4
steam enhanced catalytically cracking the light C5+ hydrocarbon stream to form a light steam enhanced catalytically cracked product including olefins, BTX, naphtha
Data Source
AI summary
In accordance with one or more embodiments herein, an integrated process for upgrading a hydrocarbon oil feed stream utilizing a delayed coker, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; delayed coking the heavy residual hydrocarbons; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a light C5+ hydrocarbon stream and a heavy C5+ hydrocarbon stream; steam enhanced catalytically cracking the light C5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.