Steam Cracker Feed Desulfurization Using Flash Separation
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Solution Overview
Problem
The high sulfur content in advantaged hydrocarbon feeds, such as crude oils, poses challenges in steam cracking processes due to increased corrosion, catalyst poisoning, and operational costs, necessitating improved systems and methods to manage sulfur-containing compositions and meet stringent product specifications.
Innovation Solution
A steam cracking process integrated with a flash separation vessel separates a sulfur-enriched stream from the hydrocarbon feed, reducing sulfur content in the pyrolysis feed and subsequent streams, using a sorbent bed to abate certain sulfur compounds and hydrogenation/hydrodesulfurization for pygas processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If advantaged feeds with high sulfur content are used for steam cracking, then feed supply increases and refinery stream dependence decreases, but corrosion and catalyst poisoning increase
Solution Approach 1:
The feed stream is divided into multiple segments with different sulfur contents. A sulfur-enriched stream is separated from the advantaged feed, allowing the remaining feed to be processed with reduced sulfur content, while the separated sulfur stream is handled through dedicated treatment processes
Solution Approach 2:
Sulfur-containing compositions are extracted and removed from the advantaged feed stream through a separation process. This extraction eliminates the harmful sulfur components before the feed enters the steam cracking furnace, preventing corrosion and catalyst poisoning while maintaining access to high-sulfur advantaged feeds
2Quantity of substance
If conventional sulfur removal methods are used, then sulfur content decreases, but processing complexity and operational costs increase
Solution Approach 1:
Sulfur removal is performed as a preliminary action before steam cracking through a flash separation process. By removing sulfur early in the process flow, subsequent processing steps are simplified and operational costs are reduced compared to post-cracking sulfur removal methods
3Quantity of substance
If sulfur-enriched stream is separated, then sulfur content in effluent decreases, but additional processing steps are required
Solution Approach 1:
The sulfur separation process is merged with the existing steam cracking process flow. The flash separation vessel is integrated into the process, allowing sulfur removal to occur in-line without requiring separate standalone processing units, thereby maintaining processing efficiency while achieving sulfur reduction
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 sulfur distribution and reduces sulfur content in steam cracker effluents, minimizing corrosion and catalyst poisoning, while enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
A flash separation vessel integrated with a steam cracking furnace separates from a primarily liquid-phase feedstock a primarily vapor-phase pyrolysis feed and a primarily liquid-phase bottoms stream
Implementation Method 2
using a sorbent bed to abate certain sulfur compounds
Implementation Method 3
hydrogenation/hydrodesulfurization for pygas processing
Implementation Method 4
The pyrolysis feed is pyrolysed under pyrolysis conditions to produce a steam cracker effluent
Data Source
AI summary
The present disclosure relates to processes, apparatuses, and systems for the removal of sulfur compounds from a heavy hydrocarbon feed as part of steam cracking processes to produce light olefins. In at least one embodiment, the process includes introducing a hydrocarbon feed having a first sulfur content to a steam cracker to produce a steam cracker effluent having a second sulfur content less than the first sulfur content. The process includes introducing the steam cracker effluent to a fractionation system to produce a light hydrocarbon product stream having a third sulfur content less than the second sulfur content.