Steam Cracker Coking Simulation Using Pressure-Loss Data
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Solution Overview
Problem
There is no effective method to determine coking in steam crackers, which affects steam cracker control, particularly distinguishing between pyrolytic and catalytic coking, and correlates with reactor tube aging and corrosion progression.
Innovation Solution
A computer-implemented method that records pressure loss and temperature profile, simulates and corrects coking based on these measurements, allowing precise determination of coking and aging of steam cracker reactor tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam cracking is stopped to free reactor tubes of coke by burning off, then coking is removed and reactor tubes are cleaned, but production is interrupted and energy consumption increases
Solution Approach 1:
The patent applies preliminary action by performing simulation calculations to determine the optimal decoking time point before critical pressure drop occurs. The system calculates pressure drop trends and predicts when decoking should be performed, allowing operators to schedule decoking proactively rather than reactively, thus minimizing production interruptions while maintaining reactor efficiency
Solution Approach 2:
The patent implements feedback by continuously monitoring pressure drop across reactor tubes and using this data to update simulation models. The system compares actual pressure drop measurements with simulated values to refine coking rate predictions, creating a closed-loop control system that optimizes decoking timing based on real-time reactor conditions
2Productivity
If more energy is supplied to heat reactor tubes, then cracking efficiency improves, but temperature resistance of reactor tubes is exceeded
Solution Approach 1:
The patent applies parameter changes by using simulation to calculate optimal operating parameters including temperature profiles, pressure drop, and space velocity. The system determines the maximum allowable heating rate that stays within reactor tube temperature limits while maximizing cracking efficiency, dynamically adjusting parameters based on real-time conditions and predicted coking rates
3Ease of operation
If coking is not monitored and optimized, then steam cracker control is difficult, but implementing monitoring increases system complexity
Solution Approach 1:
The patent applies universality by designing a simulation system that performs multiple functions: calculating pressure drop, determining coking rates, predicting decoking requirements, and optimizing operating parameters. This multi-functional approach consolidates what would otherwise require separate monitoring and control systems into a single integrated software platform, reducing overall system complexity while providing comprehensive coking management
Solution Approach 2:
The patent replaces complex physical monitoring instruments with computer-based simulation and calculation methods. Instead of installing additional sensors and physical measurement devices to detect coking, the system uses mathematical models that calculate coking rates from readily available process data (pressure drop, temperature, flow rates), substituting mechanical measurement systems with computational approaches
Data Source
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AI summary
The invention relates to a computer-implemented method for outputting the coking of a steam cracker, characterized by the following steps: a. detecting a pressure loss of the steam cracker (100), b. defining a coking of the steam cracker (101), c. simulating a pressure loss of the steam cracker based on the coking (102) defined in step b., d. correcting the coking defined in step b. to adjust the pressure loss simulated in step c. to the pressure loss (103) detected in step a., e. outputting the coking (104) corrected in step d.