Steam Cracking Furnace Vacuum Resid Integration
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Solution Overview
Problem
Conventional steam cracking processes are inefficient in processing heavy, resid-containing feeds due to fouling issues, leading to reduced conversion efficiency and increased costs, as they struggle to convert the resid fraction into higher-value olefins and aromatics.
Innovation Solution
A process integrating a vacuum resid vapor/liquid separator with a thermal conversion unit, where at least 30 wt% of the vacuum resid is converted to lighter molecules suitable for steam cracking, allowing for efficient conversion of heavy feeds to olefins and minimizing fouling by passing the thermally converted resid through a knock-out drum integrated with a steam cracking furnace.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional steam cracking processes are used to process heavy, resid-containing feeds, then the process can handle heavier crude fractions, but severe fouling occurs reducing conversion efficiency and increasing costs
Solution Approach 1:
The process segments the heavy feed processing into two distinct stages: (1) a thermal conversion zone operating at less than 649°C that converts at least 30 wt% of vacuum resid to lighter molecules, and (2) a steam cracking furnace that processes the converted material. This segmentation allows each zone to operate within optimal temperature ranges, preventing fouling in the steam cracking furnace while still achieving high conversion of heavy resid feeds.
Solution Approach 2:
The thermal conversion zone performs preliminary conversion of vacuum resid to lighter molecules before the material enters the steam cracking furnace. By pre-converting at least 30 wt% of the resid content at lower temperatures (less than 649°C), the process prepares the feed in advance to avoid severe fouling during subsequent steam cracking operations, thereby maintaining high conversion efficiency.
2Adaptability or versatility
If conventional steam cracking processes are used to process heavy, resid-containing feeds, then the process can handle heavier crude fractions, but fouling increases operational costs
Solution Approach 1:
The process divides heavy feed processing into two functional zones: a thermal conversion zone operating at less than 649°C that handles the resid conversion, and a steam cracking furnace that processes the converted material. This segmentation prevents fouling in the steam cracking furnace, eliminating the need for frequent shutdowns and costly maintenance, thereby reducing operational costs while maintaining the ability to process heavy feeds.
Solution Approach 2:
The thermal conversion zone performs preliminary processing of vacuum resid at lower temperatures before the material enters the steam cracking furnace. This pre-conversion of at least 30 wt% of resid content prevents fouling issues that would otherwise require expensive maintenance interventions, making heavy feed processing economically viable.
3Adaptability or versatility
If conventional steam cracking processes are used to process heavy, resid-containing feeds, then the process can handle heavier crude fractions, but the resid fraction conversion to higher-value materials decreases
Solution Approach 1:
The process segments resid conversion into two stages: (1) a thermal conversion zone that converts at least 30 wt% of vacuum resid to lighter molecules at temperatures below 649°C, and (2) a steam cracking furnace that further converts the thermally converted material to olefins and aromatics. This segmentation ensures high overall conversion efficiency of resid fraction to higher-value materials while preventing fouling.
Solution Approach 2:
The thermal conversion zone performs preliminary conversion of vacuum resid to lighter molecules before steam cracking. By converting at least 30 wt% of the resid content in advance at controlled temperatures (less than 649°C), the process maximizes the amount of resid that can be subsequently converted to high-value olefins and aromatics in the steam cracking furnace, thereby enhancing overall productivity.
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 process effectively converts a significant portion of heavy vacuum resid to lighter molecules, achieving high yields of olefins and aromatics while preventing fouling, thus enhancing the efficiency and economic viability of steam cracking operations.
Implementation Method 1
passing a vacuum resid containing hydrocarbon feedstock to a first thermal conversion zone where the feedstock is heated to a temperature of less than 649° C. (1200° F.), where at least 30 wt % of the vacuum resid is converted to material boiling below 566° C. (1050° F.)
Implementation Method 2
introducing said thermally converted resid to a vapor/liquid separator, said separator being in fluid communication with a steam cracking furnace, to form a vapor phase and liquid phase
Implementation Method 3
passing said vapor phase to a steam cracking furnace to thermally convert the vapor phase; recovering at least 30 wt % olefins from the material exiting the radiant furnace
Data Source
AI summary
This invention relates to a process and system for cracking hydrocarbon feedstock containing vacuum resid comprising: (a) subjecting a vacuum resid to a first thermal conversion in a thermal conversion reactor (such as delayed coker, fluid coker, Flexicoker™, visbreaker and catalytic hydrovisbreaker) where at least 30 wt % of the vacuum resid is converted to material boiling below 1050° F. (566° C.); (b) introducing said thermally converted resid to a vapor/liquid separator, said separator being integrated into a steam cracking furnace, to form a vapor phase and liquid phase; (c) passing said vapor phase to the radiant furnace in said steam cracking furnace; and (d) recovering at least 30 wt % olefins from the material exiting the radiant furnace (based upon the weight of the total hydrocarbon material exiting the radiant furnace).