Steam Cracker Feedstock Mixing for Bio-Based Olefin Production

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Solution Overview

Problem

Conventional steam crackers are not optimized for processing bio-based feedstocks like fatty acids or triglycerides, which can lead to coke formation and reduced run length due to their different composition and boiling ranges, requiring significant modifications or operating condition changes.

Innovation Solution

A process involving the mixing of a non-cyclic paraffin stream with a hydrocarbon stream to create a feedstock mixture for steam cracking, maintaining a steam to hydrocarbon ratio below 0.5 and a coil outlet temperature above 820°C, allowing for the production of high value chemicals like ethylene, propylene, and benzene without altering the steam cracker's operating conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional steam crackers process bio-based feedstocks like fatty acids or triglycerides, then high value chemicals can be produced, but coke formation increases and run length decreases

Engineering Contradiction:

Improveproduction of high value chemicalsVSAvoidrun length

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent introduces an intermediary substance (caustic wash solution or nitrogen compound) that mediates between the bio-based feedstock and the steam cracking process. This intermediary removes harmful components (oxygenates, metals) from the feedstock before cracking, preventing coke formation while allowing continuous operation. The intermediary acts as a buffer that protects the cracking system from the detrimental effects of bio-based feedstock impurities.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If conventional steam crackers process bio-based feedstocks, then high value chemicals can be produced, but significant modifications or operating condition changes are required

Engineering Contradiction:

Improveproduction of high value chemicalsVSAvoidmodifications to steam cracker

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by treating the bio-based feedstock with a caustic wash solution or nitrogen compound before introducing it to the steam cracker. This pre-treatment removes problematic components (oxygenates, metals) that would otherwise require modifications to the cracking system. By preparing the feedstock in advance, the existing steam cracker can process bio-based materials without significant structural changes.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If bio-based feedstocks with high oxygenate content are used, then renewable chemical production is achieved, but harmful factors increase leading to coke formation

Engineering Contradiction:

Improveuse of renewable feedstocksVSAvoidcoke formation

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful effect of oxygenates into a beneficial process feature. The oxygenates in bio-based feedstocks react with the caustic wash solution or nitrogen compound to form removable byproducts. This transforms the originally harmful oxygenate content into a controlled reaction that eliminates coke precursors while preserving the renewable nature of the feedstock.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Adaptability or versatility

If metal content in bio-based feedstocks is high, then processing renewable materials is achieved, but catalyst deactivation and run length reduction occur

Engineering Contradiction:

Improveprocessing of bio-based materialsVSAvoidcatalyst performance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies extraction by using a caustic wash solution or nitrogen compound to remove metal content from the bio-based feedstock before cracking. The metals are extracted into the wash solution or react with nitrogen compounds to form removable species. This separation removes the harmful metal components while retaining the valuable bio-based feedstock for cracking.

Inventive Principle:

Principle #2Taking out (Extraction)

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 enables the efficient production of high value chemicals while minimizing coke formation and extending run length, as the non-cyclic paraffins do not significantly impact the steam cracker's operating conditions, thus maintaining process efficiency and reducing the need for capital-intensive modifications.

Implementation Method 1

The vaporized feedstock is then introduced into the radiant section where the cracking takes place to produce light olefins

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 2

The hydrocarbon feedstock typically enters the convection section of the furnace as a liquid or as vapor for light feedstock's wherein it is heated and/or vaporized by indirect contact with hot flue gas

Methodology Applied

Scientific EffectHeat transfer: Convection

Data Source

PatentUS11124708B2Process for the production of high value chemicals from biologically produced materials

Publication Date: 2021.09.21 TOTAL RES & TECH FELUY SA

AI summary

The present invention relates to a process for the production of high value chemicals, preferably including at least ethylene and propylene, by steam cracking a mixture of non-cyclic paraffin stream (A) comprising at least 90% of components having at least 12 carbon atoms, with either a mixture of hydrocarbons having from 3 to 4 carbon atoms or a mixture of hydrocarbons comprising at least 90% of components having a boiling point ranging from 15° C. to 200° C.