Pyrolysis Process Contaminant Management via Neutralizing Agents
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Solution Overview
Problem
Pyrolysis processes, such as steam cracking, face challenges in handling contaminant-containing compositions like acetic acid, carbon monoxide, and carbon dioxide produced during the upgrading of low-value hydrocarbon feeds, leading to process disruptions and potential system shutdowns due to saturation and fouling.
Innovation Solution
The process involves determining the amount of contaminants in the hydrocarbon feed based on its composition, temperature, and residence time, and using neutralizing agents, amine solutions, and sorbents to separate and convert these contaminants, thereby preventing disruptions and extending the operational time of the pyrolysis system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If low-value hydrocarbon feedstocks (C5+) are used as feed to the pyrolysis unit, then operating cost is reduced, but contaminant-containing compositions (oxygenates, acetic acid, carbon monoxide, carbon dioxide) are introduced into the pyrolysis process
Solution Approach 1:
The patent determines the amount of contaminants that will be present in the steam cracker effluent based on the composition of the hydrocarbon feed, temperature, and residence time before the pyrolysis process begins. This preliminary determination allows for proactive contamination management rather than reactive treatment, enabling the system to prepare appropriate neutralizing agents and sorbents in advance to handle the expected contaminant load from low-value feedstocks.
Solution Approach 2:
The patent introduces neutralizing agents and sorbents as intermediary substances to manage the harmful contaminant-containing compositions. These intermediaries react with or adsorb the contaminants (acetic acid, carbon monoxide, carbon dioxide) to convert them into less harmful forms, thereby enabling the use of low-value feedstocks without suffering from the harmful effects of contamination.
2Adaptability or versatility
If contaminant-containing compositions are present in the pyrolysis effluent, then the pyrolysis process can handle low-value feedstocks, but process disruptions and system shutdowns occur due to saturation and fouling
Solution Approach 1:
The patent implements a feedback mechanism by continuously monitoring the composition of the hydrocarbon feed and determining the expected contaminant load in the effluent. This information feeds back into the process control system to adjust the amount of neutralizing agents and sorbents required, allowing the system to adapt to varying feed compositions while maintaining process reliability and preventing disruptions.
Solution Approach 2:
The patent changes the chemical parameters of the effluent by introducing neutralizing agents that chemically react with contaminants (e.g., neutralizing acetic acid) and sorbents that adsorb contaminant molecules. These parameter changes convert harmful contaminants into manageable substances, enabling continuous operation without fouling or saturation issues that would cause shutdowns.
3Duration of action of stationary object
If neutralizing agents and sorbents are used to manage contaminants, then fouling is reduced and operational time is extended, but additional process steps and equipment are required
Solution Approach 1:
The patent combines multiple contamination management functions into an integrated process. The determination of contaminant amounts, the selection of neutralizing agents, and the deployment of sorbents are merged into a coordinated sequence that manages multiple contaminants (acetic acid, carbon monoxide, carbon dioxide) simultaneously. This merging reduces the need for separate, standalone treatment systems for each contaminant type.
Solution Approach 2:
The patent employs sorbent materials that can adsorb multiple types of contaminant molecules (carbon monoxide, carbon dioxide, and other oxygenates) with a single material system. This multi-functional approach allows one sorbent bed or treatment unit to handle various contaminants, reducing the number of separate process steps and equipment items that would be needed if each contaminant required dedicated treatment.
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 effectively manages contaminant levels in the pyrolysis effluent, reducing fouling and allowing the steam cracking process to run for extended periods without shutdowns, thereby improving the efficiency and reliability of the pyrolysis system.
Implementation Method 1
The hydrogen-rich gas can be introduced into a methanator having a predetermined size that is sufficient to convert a majority, preferably substantially all of the first portion of carbon monoxide to methane
Implementation Method 2
a second portion of the hydrogen-rich gas can be introduced into a pressure swing adsorption unit having a predetermined size that is sufficient to remove a majority, preferably substantially all of the first portion of carbon monoxide from the hydrogen-rich gas
Implementation Method 3
The second overhead can be contacted with an amine within the amine unit having the predetermined size to remove at least 75 wt % of the carbon dioxide in the second overhead by producing a spent amine comprising a reaction product of the amine and the carbon dioxide
Data Source
AI summary
Processes for upgrading a hydrocarbon for a predetermined period of time. The process can include determining an amount of one or more contaminant-containing compositions that will be present in a pyrolysis effluent based, at least in part, on a composition of a hydrocarbon feed to be steam cracked, a. temperature the hydrocarbon feed will be heated at during steam cracking, a residence time the hydrocarbon feed will be heated at the temperature during steam cracking, or a combination thereof. In some examples, the process can also include taking one or more steps to allow the hydrocarbon feed to be steam cracked for at least as long as a predetermined, period of time, such as controlling process conditions within one or more separation stages to favor certain product compositions and/or introducing a predetermined amount of one or more materials into various locations of the process, or any combination thereof.