Steam Cracking Furnace Segmentation Without Dividing Walls
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Solution Overview
Problem
Steam cracking multiple hydrocarbon feeds within a single furnace is challenging due to the complexity and cost of dividing walls required, which limits the number of independent zones and reduces the economy of scale.
Innovation Solution
The process involves operating burners at a substantially same firing rate in different segments of a steam cracking furnace, allowing independent adjustment of hydrocarbon feed rates to control coil outlet temperatures without a dividing wall, enabling precise and localized control of steam cracking multiple hydrocarbon feeds within separate radiant coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a dividing wall is implemented to provide independent zones for multiple feeds, then multiple feed capability is achieved, but device complexity and structural requirements increase
Solution Approach 1:
The firebox is divided into multiple segments (first segment, second segment, etc.) that can independently process different hydrocarbon feeds. Each segment contains its own radiant coils and burners, allowing independent operation without requiring physical dividing walls. This segmentation achieves multiple feed capability while avoiding the structural complexity of traditional dividing wall designs.
Solution Approach 2:
Multiple feed processing functions are merged into a single firebox structure without requiring internal dividing walls. The radiant section handles multiple feeds simultaneously through coordinated burner operation, combining what would traditionally require separate furnaces or divided zones into one integrated unit, thereby reducing device complexity.
2Ease of operation
If a dividing wall is used to separate multiple feeds, then independent zone control is achieved, but plot space requirement increases
Solution Approach 1:
The firebox is segmented into multiple operational zones (first segment, second segment) that can independently control their respective feeds and temperatures. This segmentation enables independent zone control while maintaining a compact, wall-less structure that occupies less plot space than traditional divided furnace designs.
Solution Approach 2:
Instead of using dividing walls to create spatial separation, the invention uses temporal and operational segmentation - multiple feeds are processed in different segments of the same firebox through coordinated burner operation. This approach achieves independent control without the plot space penalty of physical barriers.
3Device complexity
If multiple feeds are cracked in different segments without dividing walls, then device complexity is reduced, but heat distribution control becomes more challenging
Solution Approach 1:
The system employs feedback control where the feed rate of each hydrocarbon feed is controlled based on the coil outlet temperature. This feedback mechanism enables precise heat distribution control across multiple segments without complex dividing wall structures, as the control system automatically adjusts feed rates to maintain desired temperatures.
Solution Approach 2:
The burners in different segments are operated at substantially the same firing rate, creating a dynamic balancing act that maintains uniform heat distribution. The system dynamically adjusts burner operation and feed rates to compensate for the absence of dividing walls, achieving control through operational flexibility rather than structural constraints.
4Stability of the object's composition
If burners are operated at substantially the same firing rate, then heat production uniformity is achieved, but adjustment flexibility for different feed compositions is reduced
Solution Approach 1:
The system achieves both heat production uniformity and feed composition adaptability by changing operational parameters - specifically, the feed rate of each hydrocarbon feed is controlled based on its composition and the coil outlet temperature. This allows the system to maintain uniform burner firing rates while adjusting feed rates to accommodate different feed compositions.
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 allows for efficient steam cracking of multiple hydrocarbon feeds with precise control, reducing the need for dividing walls, minimizing space and cost, and maintaining economy of scale, while also mitigating risks like furnace flooding and tube overheating.
Implementation Method 1
The first segment can include one or more burners providing heat thereto. The second segment can include one or more burners providing heat thereto.
Implementation Method 2
introducing a first hydrocarbon feed into one or more radiant coils disposed within a first segment of a firebox
Implementation Method 3
one or more radiant coils disposed within a first segment of a firebox of a steam cracker
Implementation Method 4
Steam cracking is the primary means to generate ethylene and other products from a variety of feedstocks
Data Source
AI summary
Processes and systems for steam cracking hydrocarbon feeds. The process can include introducing a first hydrocarbon feed into radiant coil(s) disposed within a first segment of a firebox to produce a first steam cracker effluent having a first coil outlet temperature. A second hydrocarbon feed can be introduced into radiant coil(s) disposed within a second segment of the firebox to produce a second steam cracker effluent having a second coil outlet temperature. The first and second segments can each include one or more burners providing heat thereto. The burner(s) in each segment can be operated at substantially the same firing rate such that an amount of heat produced by each burner can be substantially the same. A feed rate of the first hydrocarbon feed can be controlled based, at least in part, on a composition of the first hydrocarbon feed and the first coil outlet temperature.