Olefin Cracking Catalyst System for Lower Olefin Yield
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Solution Overview
Problem
Current methods for producing lower olefins like ethylene and propylene from petroleum saturated hydrocarbons, such as steam cracking and catalytic cracking, face challenges including high energy consumption, catalyst deactivation, and high investment costs, with existing technologies not efficiently reducing energy and raw material usage while enhancing yield.
Innovation Solution
A process involving dehydrogenation of petroleum saturated hydrocarbons with a dehydrogenation catalyst at 400-600°C followed by olefin cracking with an olefin cracking catalyst, using a mixture of C4-C35 hydrocarbons, with specific conditions to achieve a conversion rate of at least 45% and subsequent separation of C2-C4 olefins to enhance ethylene and propylene yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam cracking method is used to produce lower olefins, then the production volume is high (99% of ethylene and 50% of propylene), but the energy consumption is very high due to maximum tube metal temperature reaching 1125°C and complicated separation processes
Solution Approach 1:
The patent changes the fundamental reaction parameters by using catalytic cracking instead of thermal steam cracking, operating at lower temperatures (500-750°C vs 1125°C) and using catalysts to alter the reaction pathway, thereby reducing energy consumption while maintaining productivity
Solution Approach 2:
The patent introduces catalysts as intermediaries to facilitate the cracking reaction, allowing the process to proceed at lower temperatures and with different product distribution, reducing the need for high-energy separation processes
2Manufacturing precision
If fixed bed catalytic cracking methods are used to produce lower olefins, then the selectivity of desired products is improved and cracking temperature is reduced, but the solid catalyst causes uneven heat distribution and coking results in catalyst deactivation
Solution Approach 1:
The patent transitions from a static fixed bed catalyst system to a dynamic fluidized bed system where catalyst particles are continuously circulated, regenerated, and reused, maintaining consistent activity and preventing localized coking
Solution Approach 2:
The patent implements catalyst regeneration by discarding deactivated catalyst particles and recovering them through continuous circulation, where spent catalyst is regenerated in a separate reactor and returned to the cracking reactor, maintaining long-term reliability
3Productivity
If fixed bed catalytic cracking technologies are used, then the yield of desired products is increased and cracking reaction temperature is decreased, but investment costs for building a catalytic cracking furnace are remarkably higher than steam cracking furnace
Solution Approach 1:
The patent designs a fluidized catalytic cracking system that can process multiple feedstock types (naphtha, gas oil, vacuum gas oil) and produce multiple products (ethylene, propylene, gasoline, diesel) from a single integrated facility, improving economic viability
Solution Approach 2:
The patent implements continuous operation with catalyst circulation and regeneration, eliminating downtime for catalyst replacement and maintaining continuous production, thereby improving productivity and reducing per-unit costs
4Productivity
If conventional steam cracking or catalytic cracking is used, then lower olefins are produced, but the amount of small molecules (hydrogen and methane) is relatively great (about 15mol%), requiring high energy consumption for separation
Solution Approach 1:
The patent changes the reaction conditions and catalyst system to alter product distribution, reducing the formation of light gases (hydrogen and methane) through optimized catalytic cracking parameters and temperature control
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 energy consumption, lowers reaction temperatures, and increases the yield of ethylene and propylene, while minimizing hydrogen and methane generation, thus reducing separation energy and investment costs, and is more efficient than conventional methods.
Implementation Method 1
contacting a preheated petroleum saturated hydrocarbons feedstock with a dehydrogenation catalyst in a dehydrogenation reaction zone of a reaction system to obtain a petroleum hydrocarbon stream containing unsaturated hydrocarbon compounds wherein the dehydrogenation reaction is performed at a temperature of 400 - 600°C
Implementation Method 2
the petroleum hydrocarbon stream containing the unsaturated hydrocarbon compounds together with a diluent is fed into the olefin cracking reaction zone to contact with the olefin cracking catalyst in the olefin cracking reaction zone to obtain olefins with a reduced number of carbon atoms
Data Source
Figure 1~2
AI summary
The present invention discloses a process for producing olefins from petroleum saturated hydrocarbons. The process of the present invention comprises: contacting a preheated petroleum saturated hydrocarbons feedstock with a dehydrogenation catalyst in a dehydrogenation reaction zone of a reaction system to obtain a petroleum hydrocarbon stream containing unsaturated hydrocarbon compounds, in which the dehydrogenation reaction has a conversion rate of at least 20%; and contacting the obtained petroleum hydrocarbon stream containing the unsaturated hydrocarbon compounds with olefins cracking catalyst in an olefin cracking zone of the reaction system to obtain a product stream containing olefins with a reduced number of carbon atoms.