Steam-Assisted Condensate Cracking for Olefin and Diesel Production
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Solution Overview
Problem
The processing of condensate feedstock to produce diesel requires high capital investment and significant energy consumption due to the use of crude distillation columns and steam cracking reactors, which are energy-intensive and costly.
Innovation Solution
A process involving volatilization of hydrocarbons with steam, followed by vacuum distillation and hydroprocessing, to separate and convert hydrocarbons into olefins, diesel, and pyrolysis oil, using a HOPS tower and steam cracking reactor, reducing energy demands and capital costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a crude distillation column with many trays is used to fractionate condensate, then diesel production is achieved, but capital investment and energy consumption increase significantly
Solution Approach 1:
The process divides the condensate into different fractions (light VGO, heavy VGO, vacuum residue) through vacuum distillation, then selectively processes each fraction. This segmentation allows the steam cracking unit to receive optimized feedstock mixtures, improving diesel production efficiency while reducing the energy-intensive operations required in conventional single-stream processing
Solution Approach 2:
The patent operates the steam cracking unit at elevated temperatures (800-900°C) with controlled residence times and steam-to-hydrocarbon ratios. These parameter optimizations enable efficient conversion of hydrocarbons to olefins and diesel components with reduced energy consumption compared to conventional cracking processes
2Productivity
If steam cracking reactors are operated to convert hydrocarbons, then olefins and diesel are produced, but fuel consumption increases
Solution Approach 1:
The condensate is pre-vacuum distilled to separate and concentrate the hydrocarbon fractions before entering the steam cracking unit. This preliminary action ensures the cracking reactor receives optimized feedstock with appropriate composition and concentration, improving conversion efficiency and reducing the fuel required for the cracking process
Solution Approach 2:
The process maintains continuous operation of the steam cracking unit with steady-state conditions, optimizing the conversion of hydrocarbons to olefins and diesel. The continuous processing of cracked products and recycling of unreacted materials ensures maximum utilization of feedstock and minimizes energy waste
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 maximizes EURO-V diesel production while minimizing VLSFO production with reduced financial investment and increased energy efficiency, and lowers CO2 emissions.
Implementation Method 1
contacting a condensate feedstock with steam to volatilize a portion of the hydrocarbons
Implementation Method 2
fractionating the liquid phase in a vacuum distillation column into one or more distillate fractions
Implementation Method 3
feeding the hydroprocessed light VGO fraction, the hydroprocessed heavy VGO fraction, and the vapor phase to a steam cracking reactor to convert at least a portion of the hydrocarbons therein to a steam cracker effluent comprising one or more olefins and a pyrolysis oil stream
Data Source
AI summary
A process for processing condensate feedstock into one or more products including contacting condensate feedstock with steam; recovering in a volatilization device a vapor phase of hydrocarbons with a boiling point of less than 300° C. and a liquid phase of unvaporized hydrocarbons with a boiling point of greater than 300° C.; fractionating the liquid phase in a vacuum distillation column into one or more distillate fractions; hydroprocessing a light and a heavy VGO fraction in a hydroprocessing system to produce a hydroprocessed light and a hydroprocessed heavy VGO fraction and a diesel fraction; collecting the vacuum residue of the vacuum distillation column; and feeding the hydroprocessed heavy and light VGO fractions and the vapor phase to a steam cracking reactor to convert at least a portion of the hydrocarbons to one or more olefins and a pyrolysis oil stream.