Fluidized Particle Pyrolysis for Heavy Hydrocarbon Olefin Upgrading
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Solution Overview
Problem
Conventional pyrolysis furnaces struggle to process hydrocarbon-containing feeds with non-volatile components, leading to fouling and inefficiencies, and fail to effectively convert low-cost heavy crude oil into valuable chemicals like olefins due to the extensive and expensive processing required.
Innovation Solution
A process involving pyrolysis and gasification/combustion, where a hydrocarbon-containing feed is contacted with particles in a pyrolysis zone to produce olefins, with coke formation on the particles, followed by gasification/combustion to regenerate particles and produce a gasification/combustion gas mixture, and subsequent oligomerization of olefins using catalysts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pyrolysis furnaces are used to process hydrocarbon-containing feeds with non-volatile components, then olefins can be produced, but fouling occurs in the radiant section and processing becomes inefficient
Solution Approach 1:
The process separates the pyrolysis function from the heating function by using a fluidized bed reactor with externally heated particles. The particles are heated externally in a separate heating zone, then circulated to the pyrolysis zone where they transfer heat to the hydrocarbon feed without direct contact with the feed, preventing fouling while maintaining high olefin production efficiency.
Solution Approach 2:
Inert particles (such as sand, alumina, or silica) serve as intermediaries to transfer thermal energy from the heating zone to the hydrocarbon feed in the pyrolysis zone. These particles do not react with the feed and can be continuously circulated and regenerated, eliminating direct contact between the feed and heating surfaces that causes fouling.
2Object-affected harmful factors
If external vaporization drums are used to separate vaporized hydrocarbons from liquid hydrocarbons to address fouling, then fouling is reduced, but liquid hydrocarbons containing substantial quantities of hydrocarbons are removed and used as fuel instead of being converted to valuable olefins
Solution Approach 1:
The fluidized bed reactor performs multiple functions simultaneously: it vaporizes the liquid hydrocarbon feed, cracks it to produce olefins, and handles feeds with high non-volatile content without requiring separate vaporization drums. This integrated approach converts the entire feed stream including previously discarded liquid fractions into valuable olefins.
Solution Approach 2:
The process changes the operating parameters (temperature, residence time, particle circulation rate) to optimize the conversion of liquid hydrocarbons into olefins. By controlling the pyrolysis conditions in the fluidized bed, the system achieves high conversion efficiency for feeds that would otherwise be discarded as fuel.
3Object-affected harmful factors
If heavy crude oil with non-volatiles is processed through extensive conventional processing, then fouling is managed, but the processing becomes expensive and value is lost
Solution Approach 1:
The system maintains continuous circulation and regeneration of heating particles, allowing uninterrupted processing of heavy crude oil feeds. The particles are continuously heated, circulated to the pyrolysis zone, regenerated, and reused, enabling continuous conversion of challenging feeds without shutdowns for maintenance or complex batch processing.
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 enables the production of valuable olefins and oligomers from hydrocarbon feeds, including residues and crudes, while managing fouling and extending the life of catalysts, offering flexibility in switching between olefin and fuel production based on market demands.
Implementation Method 1
contacting the hydrocarbon-containing feed stream with the particles in the pyrolysis zone under pyrolysis conditions to effect pyrolysis of at least a portion of the C2+ hydrocarbons to produce a pyrolysis zone effluent that can include olefins and the particles, where coke can be formed on the surface of the particles
Implementation Method 2
contacting the first particle stream, the oxidant stream, and optionally the first steam stream in the gasification/combustion zone under gasification/combustion conditions to produce a gasification/combustion zone effluent comprising regenerated particles and a gasification/combustion gas mixture
Data Source
AI summary
Processes for upgrading a hydrocarbon-containing feed. The feed and a first particle stream can be contacted under pyrolysis conditions to effect pyrolysis of the feed to produce a pyrolysis effluent that can include olefins and the particles, where coke can be formed on the particles. A first gaseous stream and a second particle stream can be obtained from the pyrolysis effluent. At least a portion of the first gaseous stream can be contacted with oligomerization catalyst particles under oligomerization conditions to effect oligomerization of at least a portion of olefins in the first gaseous stream.