Propane Hydrogen Thermal Cracking for Ethylene Production
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Solution Overview
Problem
Current thermal cracking processes using fossil-based feeds are environmentally unsustainable, and there is a need for alternative methods to utilize gaseous side products from renewable naphtha and diesel range feeds, which are typically burnt as fuel gas.
Innovation Solution
A thermal cracking method using a feed comprising molecular hydrogen and 10-60 mol-% propane, with a propane to hydrogen ratio of 0.10-2.5, to produce a thermal cracking effluent rich in ethylene and propylene, while minimizing coke formation and enhancing process economy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gaseous side products from renewable naphtha and diesel range feeds are burnt as fuel gas, then energy is recovered, but value added use is not achieved and environmental sustainability is limited
Solution Approach 1:
The patent changes the application parameter of gaseous side products from combustion (fuel gas) to thermal cracking feedstock. This parameter change enables the production of valuable chemical intermediates (ethylene, propylene) while maintaining environmental sustainability by utilizing renewable feedstock derivatives.
Solution Approach 2:
The patent converts what was previously considered a low-value byproduct (gaseous side products destined for combustion) into a valuable resource for chemical production. By redirecting these gases to thermal cracking, the process transforms a limited utility stream into a source of high-value chemicals, achieving both economic and environmental benefits.
2Productivity
If thermal cracking is performed with conventional feeds, then ethylene and propylene are produced, but fossil-based resources are consumed and environmental sustainability is compromised
Solution Approach 1:
The patent changes the feedstock parameter from conventional fossil-based feeds to gaseous side products from renewable naphtha and diesel range feeds. This parameter change maintains productive output (ethylene and propylene production) while improving environmental sustainability by utilizing renewable resources.
3Productivity
If propane content in thermal cracking feed is increased, then ethylene yield is improved, but coking rate increases and process efficiency decreases
Solution Approach 1:
The patent optimizes the propane content parameter within a specific range (10-60 mol-%) rather than using high propane content feeds. This parameter optimization achieves satisfactory ethylene yield while controlling the coking rate, thereby maintaining process efficiency and reducing harmful coke formation.
Solution Approach 2:
The patent applies local quality by creating a specific compositional profile for the thermal cracking feed, combining propane with other components in controlled proportions. This localized composition optimization ensures that ethylene production is enhanced while coking is suppressed, rather than simply increasing overall propane content.
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 method achieves high propane conversion, selectivity towards ethylene, and low coking rates, providing a cost-effective and sustainable production of valuable hydrocarbons from renewable sources, with a high specific yield of C2 hydrocarbons and reduced formation of undesirable C5+ compounds.
Implementation Method 1
subjecting the thermal cracking feed to thermal cracking to obtain a thermal cracking effluent comprising ethylene
Data Source
AI summary
Thermal cracking of a feed that contains propane and molecular hydrogen is disclosed. Also, a thermal cracking feed and a thermal cracking effluent are provided.