Steam Cracking Compressor Drive Standardization for Reduced Emissions
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Solution Overview
Problem
Existing steam cracking methods for producing ethylene and olefins face challenges in energy efficiency, carbon dioxide emissions, and inflexibility due to rigid steam utilization and high structural complexity, particularly in the use of high-pressure steam boilers and condensation steam turbines.
Innovation Solution
The method employs two serial compressor trains for crude gas and refrigerant compression, driven by electrical drives with identical power features and frequency converters, allowing for flexible operation and reduced carbon dioxide emissions by eliminating high-pressure steam boilers, and utilizing waste heat for other processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-pressure steam boilers and condensation steam turbines are used for driving compressors, then reliable power supply is ensured, but device complexity and carbon dioxide emissions increase
Solution Approach 1:
The patent extracts and eliminates the high-pressure steam boiler and condensation steam turbine from the system, replacing them with electric drives. This removes the complex steam generation and utilization infrastructure while maintaining compressor operation, thereby reducing device complexity and carbon dioxide emissions without compromising power supply reliability.
Solution Approach 2:
The patent substitutes the mechanical steam turbine drive system with an electric drive system. Instead of using thermal energy from steam to mechanically drive compressors, the invention uses electrical energy to directly power the compressors through electric motors, simplifying the overall system architecture and reducing harmful emissions.
2Adaptability or versatility
If different compressor drives with varying power features are used, then specific process requirements are met, but manufacturing and maintenance complexity increase
Solution Approach 1:
The patent applies homogeneity by using compressor drives with identical or at least partially identical power features across different compressor units. This standardization simplifies manufacturing, procurement, and maintenance processes. The system achieves process adaptability not through drive diversity but through the flexibility of variable-speed electric drives that can be uniformly controlled to meet different process requirements.
Solution Approach 2:
The patent makes the compressor drives universal by designing them with identical power features and using frequency converters that can adapt the same drive design to different operating conditions. This universal drive design serves multiple functions and positions, reducing the need for specialized drive designs for each compressor unit, thereby simplifying manufacturing and maintenance while maintaining process versatility.
3Device complexity
If fixed-speed compressor drives are used, then simple construction is achieved, but energy efficiency and operational flexibility decrease
Solution Approach 1:
The patent transitions from static fixed-speed drives to dynamic variable-speed electric drives. These drives can adjust their operating speed and power output according to actual process requirements, significantly improving energy efficiency. The added complexity of variable-speed control is offset by the elimination of complex mechanical speed-change mechanisms, and the system gains operational flexibility to optimize energy consumption across different loading conditions.
Solution Approach 2:
The patent changes the operating parameters of the compressor drives by using frequency converters to control electric motors. Instead of fixed speed and power parameters, the system can dynamically adjust electrical parameters (frequency, voltage, current) to match process demands, improving energy efficiency while maintaining relatively simple drive construction through standardized electric motor and converter components.
4Quantity of substance
If high-pressure steam boilers are used for heat supply, then sufficient thermal energy is provided, but carbon dioxide emissions and energy loss increase
Solution Approach 1:
The patent converts the previously wasted low-pressure steam into a useful resource. Instead of venting or condensing low-pressure steam without utilization, the system now uses it to drive the C2 and C3 refrigerant compressors via steam turbines. This converts what would be harmful emissions and energy loss into beneficial mechanical work, reducing carbon dioxide emissions from fossil fuel-based steam boilers while maintaining sufficient thermal energy supply.
Solution Approach 2:
The patent implements self-service by using the plant's own waste heat and low-pressure steam to power the refrigerant compressors. The system serves itself by utilizing internally generated thermal energy that would otherwise be wasted, reducing the need for external fossil fuel combustion and associated carbon dioxide emissions while maintaining adequate thermal energy supply for process requirements.
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 enhances energy efficiency, reduces carbon dioxide emissions, and improves plant flexibility by standardizing compressor drives, enabling efficient ethylene and olefin production with reduced fossil energy demand and simplified maintenance.
Implementation Method 1
a method for producing ethylene and/or other olefins by steam cracking
Implementation Method 2
The C2 refrigerant is compressed using a C2 refrigerant compressor. The C3 refrigerant is compressed using a C3 refrigerant compressor.
Data Source
AI summary
A method for producing ethylene and/or other olefins by steam cracking includes charging one or more crackers with a paraffin-containing feed and withdrawing a crude gas from the one or more crackers. The crude gas is subjected at least in part to a treatment comprising a crude gas compression and a thermal separation using a C2 refrigerant and a C3 refrigerant. A crude gas compressor is used for the crude gas compression, wherein the ethylene refrigerant is compressed using a C2 refrigerant compressor. The propylene refrigerant is compressed using a C3 refrigerant compressor. The crude gas compressor comprises two serial compressor trains. The compressor trains, the C2 refrigerant compressor and the C3 refrigerant compressor are each operated at least in part using electrical drives, which have at least partially identical power features, are provided as variable-speed drives of the same construction, and are each fed via frequency converters.