Integrated Steam Cracking and Distillation for Crude Oil Valorization
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Solution Overview
Problem
Current refinery processes for crude oil are inefficient in utilizing all fractions obtained during atmospheric and vacuum distillation, leading to suboptimal production of high-value crude oil products due to incomplete valorization of compounds.
Innovation Solution
A method and apparatus that involve subjecting a gaseous stream from crude oil to steam cracking, followed by quenching with a liquid hydrocarbon stream to form a quenching effluent, which is then integrated into distillation with a second crude oil stream for joint separation, eliminating the need for separate separation devices and reducing apparatus expenditure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate quenching and separation circuits are used in conventional refinery processes, then the cracking process can be carried out, but the apparatus complexity and expenditure increase
Solution Approach 1:
The patent merges the quenching circuit and separation circuit into a single integrated distillation column. The quenching effluent from the steam cracking process is fed directly into the distillation column where separation occurs simultaneously, eliminating the need for separate quenching and separation equipment. This integration reduces apparatus complexity and expenditure while maintaining process functionality.
Solution Approach 2:
The distillation column performs multiple functions: it acts as both a separation device for dividing the quenching effluent into fractions and as a processing unit for handling the cracked gas stream. This multi-functionality eliminates the need for dedicated separate circuits, reducing overall device complexity while achieving the same technical objectives.
2Productivity
If all fractions from atmospheric and vacuum distillation are utilized in conventional processes, then production continues, but the yield of high-value crude oil products is suboptimal
Solution Approach 1:
The patent applies steam cracking parameters to transform unvalorized compounds from atmospheric and vacuum distillation into high-value products. By changing the processing parameters from conventional thermal reactions to steam cracking conditions (high temperature, steam atmosphere), previously unvalorized fractions are converted into valuable chemicals, increasing productivity while reducing substance loss.
Solution Approach 2:
The patent converts what were previously considered waste or unvalorized compounds from distillation processes into valuable products through steam cracking. The unvalorized fractions that could not be profitably utilized in conventional processes are transformed into high-value crude oil products, turning a disadvantage into a benefit and increasing overall yield.
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 increases the yield of high-value crude oil products by fully integrating the quenching effluent into refinery processes, reducing the need for separate separation and quenching circuits, and enabling direct processing of the quenching effluent, thus enhancing energy integration and reducing waste heat.
Implementation Method 1
a gaseous stream formed during evaporation of a crude oil stream is subjected, at least partially, to a steam cracking process
Implementation Method 2
The cracked gas stream obtained is at least partially quenched with a liquid hydrocarbon stream, thereby forming a quenching effluent
Implementation Method 3
the separation feed together with a second crude oil stream is separated by distillation, forming distillation effluents
Data Source
AI summary
A method for obtaining crude oil products is proposed in which a gaseous stream (d) is formed from a first crude oil stream (b) and the gaseous stream (d) is at least partially subjected to a steam cracking process (1) in which a cracked gas stream (e) is produced which is at least partially quenched with a liquid hydrocarbon stream (f), thereby forming a quenching effluent (g). It is provided that at least part of the quenching effluent (g) is used to form a separation feed and that the separation feed is separated by distillation (5, 8) together with a second crude oil stream (c), forming distillation effluents (h, i, k, p, r). The separation feed is formed so that it contains hydrocarbons having one, two, three, four or more carbon atoms contained in the quenching effluent (g) and/or hydrocarbons formed from such hydrocarbons. The invention also relates to an apparatus (100) configured to carry out the method.