Olefin-Paraffin Separation for FCC Cracking Efficiency

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Fluidized catalytic cracking (FCC) systems face inefficiencies in processing paraffin/olefin mixtures, leading to high capital expenses and energy consumption due to the recycling of unconverted paraffins, which results in a buildup of recycle material and lower conversion rates compared to olefins.

Innovation Solution

A method and system for separating olefins and paraffins to produce an olefin-rich and a paraffin-rich hydrocarbon stream, followed by cracking the olefin-rich stream in the presence of catalysts to enhance the yield of C2-C3 olefins, utilizing multi-bed adsorption and fractionation processes to optimize hydrocarbon processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If paraffins are recycled to extinction in FCC systems, then olefin conversion is maximized, but capital expenses and energy consumption increase due to buildup of recycle material

Engineering Contradiction:

Improveolefin conversionVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by stationary object

Solution Approach 1:

The patent extracts paraffins from the paraffin/olefin mixture through selective separation before the FCC process. By removing paraffins from the recycle stream, the system avoids the energy-intensive buildup of recycle material while maintaining high olefin conversion rates in the FCC reactor.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent segments the hydrocarbon feed into paraffin-rich and olefin-rich streams through selective separation. This segmentation allows the olefin-rich stream to be processed in the FCC system for maximum conversion while the paraffin-rich stream is handled separately, reducing the overall recycle burden and energy consumption.

Inventive Principle:

Principle #1Segmentation

2Productivity

If paraffins are recycled to extinction, then olefin conversion is maximized, but capital expenses increase due to buildup of recycle material

Engineering Contradiction:

Improveolefin conversionVSAvoidcapital expenses

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent extracts paraffins from the recycle stream using selective separation technology. This extraction reduces the volume of material requiring extensive recycling infrastructure, thereby lowering capital expenses while maintaining high olefin conversion efficiency.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent performs preliminary separation of paraffins from olefins before the FCC process. By pre-separating the components, the system avoids the need for large-scale recycle infrastructure and extinction reactors, reducing capital expenses while achieving the same conversion goals more efficiently.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If paraffin conversion is increased in FCC systems, then overall hydrocarbon utilization improves, but selectivity for C2-C3 olefins decreases

Engineering Contradiction:

Improveparaffin conversionVSAvoidselectivity for C2-C3 olefins

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent segments the feedstock into paraffin-rich and olefin-rich streams. The olefin-rich stream is directed to the FCC process where it achieves high conversion to C2-C3 olefins with excellent selectivity, while the paraffin-rich stream is processed separately or recycled, allowing optimization of each stream for its specific purpose.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different processing conditions to different streams. The olefin-rich stream receives FCC treatment optimized for C2-C3 olefin production, while the paraffin-rich stream is handled differently. This local optimization ensures high selectivity for the desired products without compromising overall paraffin utilization.

Inventive Principle:

Principle #3Local quality

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 improves the conversion efficiency of paraffins, reduces capital and energy costs, and maximizes the yield of propylene and ethylene by effectively separating and processing the hydrocarbon streams, thereby enhancing the overall performance of FCC systems.

Implementation Method 1

passing the hydrocarbon feed through an adsorption system to separate olefins from the feed

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

passing the olefin-rich stream through a fractionation system to separate C2-C4 olefins from C5+ olefins

Methodology Applied

Scientific EffectFractionation: Fractionation

Implementation Method 3

cracking the C2-C4 olefin stream to produce a cracked gas containing C2-C3 olefins

Methodology Applied

Scientific EffectCatalytic cracking: Catalysis

Data Source

PatentUS8889942B2Integrated light olefin separation/cracking process

Publication Date: 2014.11.18 KELLOGG BROWN & ROOT INC

AI summary

Systems and methods for producing a hydrocarbon are provided. The method can include separating a hydrocarbon comprising olefins and paraffins to produce an olefin-rich hydrocarbon comprising about 70 wt % or more olefins and a paraffin-rich hydrocarbon comprising about 70 wt % or more paraffins. The method can also include cracking at least a portion of the olefin-rich hydrocarbon in the presence of one or more catalysts at conditions sufficient to produce a cracked product comprising about 20 wt % or more C2-C3 olefins.