Single-Stage Hydrocracking for Ring Opening and Light Olefins
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Solution Overview
Problem
Existing hydrocracking processes face challenges with feed limitations, particularly in producing light olefins like ethylene and propylene, due to the presence of heavy polynuclear aromatics that cause fouling and coking, and the inefficiency of steam cracking operations, leading to low yields of valuable products.
Innovation Solution
A hydrocracking process that converts at least 95 vol % of rings in a feed stream to aliphatic hydrocarbons, using a single-stage hydrocracking unit with specific catalysts and conditions to produce a hydrocracked effluent stream suitable for producing light olefins, bypassing the formation of multi-ring aromatics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam cracking is used to produce ethylene and propylene from hydrocarbons, then light olefin production is achieved, but heavy polynuclear aromatics cause fouling of exchangers and coking on catalyst
Solution Approach 1:
The patent applies preliminary action by performing hydrocracking treatment before steam cracking. The hydrocracking unit pre-processes the feedstock to convert heavy polynuclear aromatics into lighter, less problematic compounds, preventing fouling and coking issues in subsequent steam cracking operations while maintaining light olefin production efficiency
2Productivity
If conventional hydrocracking processes are used, then heavy polynuclear aromatics are present in the effluent, but these aromatics cause adverse impact on hydrocracking operations
Solution Approach 1:
The patent applies parameter changes by modifying hydrocracking conditions including temperature (350-450°C), pressure (30-200 atm), and catalyst composition (bifunctional catalyst with metal function and acid function) to optimize the conversion of heavy polynuclear aromatics while minimizing the formation of compounds that cause fouling and coking
3Adaptability or versatility
If hydrotreated heavier crude components are used in steam crackers, then feed availability is improved, but ethylene yield is reduced
Solution Approach 1:
The patent applies segmentation by dividing the processing into two distinct stages: first, hydrocracking to convert heavy polynuclear aromatics into lighter compounds; second, steam cracking to produce ethylene. This segmentation allows the use of heavier crude components while maintaining high ethylene yield by preventing the formation of problematic aromatic compounds in the steam cracker feed
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
The process effectively saturates aromatics and opens naphthene rings, enhancing the yield of light olefins and producing a hydrocracked effluent stream primarily composed of aliphatic hydrocarbons, addressing feed limitations and improving the production of valuable chemicals like ethylene and propylene.
Implementation Method 1
hydrocracking various feed streams in a hydrocracking reactor over a hydrocracking catalyst in the presence of a hydrocracking hydrogen stream at hydrocracking conditions
Implementation Method 2
hydrocracking a feed stream over a hydrocracking catalyst in the presence of a hydrocracking hydrogen stream to open at least 95 vol % of all rings present in the feed stream
Data Source
AI summary
A process of hydrocracking a feed stream is provided. The hydrocracking process comprises hydrocracking a feed stream in a hydrocracking reactor over a hydrocracking catalyst in the presence of a hydrocracking hydrogen stream at hydrocracking conditions to open at least 95 vol % of all rings present in the feed stream to produce a hydrocracked effluent stream that is aliphatic. The feed stream to the hydrocracking process may comprise more than one feedstock. The feed stream to the hydrocracking process may comprise a petroleum origin feed or a bio-based feed or a combination of both.