Pyrolysis Effluent Inertial Separation for Coke Particle Removal
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Solution Overview
Problem
The presence of coke particles in pyrolysis effluents, such as steam cracker effluents, leads to erosion in hydrocarbon separation equipment and accumulation in recovery systems, necessitating improved methods for their removal during online decoking.
Innovation Solution
A process and system utilizing inertial separation techniques to separate coke particles from pyrolysis effluents by controlling the Stokes number of particles and adjusting flow conditions in a separator with angled exit conduits, allowing for efficient recovery of coke particles and a lean hydrocarbon effluent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam-air-decoking is performed online to remove coke from radiant coils, then coke removal efficiency is improved, but coke particles enter the hydrocarbon recovery system causing erosion and accumulation
Solution Approach 1:
The patent extracts and removes coke particles from the effluent stream using a separator device positioned in the hydrocarbon recovery system. The separator utilizes inertial separation to extract ≥55 wt.% of coke particles from the combined effluent, preventing them from entering downstream equipment and causing erosion or accumulation.
Solution Approach 2:
The patent introduces an intermediary separation system between the decoking process and the hydrocarbon recovery equipment. This intermediary separator acts as a protective barrier, capturing coke particles before they can reach and erode the hydrocarbon separation equipment and recovery system.
2Adaptability or versatility
If decoking effluent is mixed with hydrocarbon effluent and introduced into the recovery system, then online decoking is enabled, but coke particles cause erosion in separation equipment
Solution Approach 1:
The separator device extracts coke particles from the mixed effluent stream containing both hydrocarbons and decoking byproducts. By removing ≥55 wt.% of coke particles before the effluent enters the hydrocarbon separation equipment, the system enables online decoking while protecting downstream equipment from erosion.
Solution Approach 2:
The separator serves as an intermediary treatment stage between the decoking process and the hydrocarbon recovery system. It mediates the interaction by filtering out harmful coke particles while allowing the decoking effluent to be processed alongside hydrocarbon effluent, thus enabling online decoking operation.
3Device complexity
If traditional separation methods are used, then equipment complexity is minimized, but coke particle removal efficiency is insufficient
Solution Approach 1:
The patent replaces complex mechanical separation systems with an inertial separation mechanism based on Stokes number principles. This substitution achieves high coke particle removal efficiency (≥55 wt.%) through a relatively simple separator design with angled exit conduits, minimizing device complexity while maximizing removal effectiveness.
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
Achieves high separation efficiency, with ≥80 wt.% of coke particles with a Stokes number ≥10 being recovered from one exit conduit and ≤45 wt.% in the other, effectively reducing equipment erosion and system accumulation.
Implementation Method 1
A process and system utilizing inertial separation techniques to separate coke particles from pyrolysis effluents by controlling the Stokes number of particles
Implementation Method 2
Heat can be indirectly exchanged from the second hydrocarbon effluent to water, steam, or a mixture thereof to produce a cooled second hydrocarbon effluent. Heat can be indirectly exchanged from the de-coking effluent to water, steam, or a mixture thereof to produce a cooled de-coking effluent.
Data Source
AI summary
Processes and systems for pyrolysing a hydrocarbon. In some examples, the process can include mixing a cooled hydrocarbon effluent and a cooled de-coking effluent to produce a combined effluent. The combined effluent can be introduced into an inlet conduit of a separator under conditions that provide >80 wt. % of the plurality of coke particles with a Stokes number of >10. From a first exit conduit of the separator >55 wt. % of the plurality of coke particles in the combined effluent can be removed, and from a second exit conduit of the separator a coke-lean hydrocarbon effluent that includes <45 wt. % of the plurality of coke particles in the combined effluent can be removed. The first exit conduit and the second exit conduit can be coupled to the inlet conduit.