Thermal Hydroprocessing Crude Oil to Olefins
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Solution Overview
Problem
Current hydrocracking, fluid catalytic cracking, and steam cracking processes for converting crude oil to chemicals are inefficient, requiring multiple steps, high investment costs, and significant fuel consumption, with suboptimal production of high-value chemicals like ethylene and propylene.
Innovation Solution
A thermal hydro-processing method using hydrogen and water/steam to upgrade crude oils and residues, with a solvent to keep asphaltenes in solution, converting hydrocarbons to lighter molecules, and further processing these upgraded products to produce ethylene, propylene, and benzene in a streamlined process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple feed preparation units (hydrocrackers, cokers, hydrotreaters) are used for upgrading heavy ends, then the conversion of crude oil to chemicals is achieved, but the process complexity and investment costs increase significantly
Solution Approach 1:
The patent combines multiple feed preparation units (hydrocracker, coker, hydrotreater) into a single integrated processing unit that performs upgrading, hydrocracking, and hydrodesulfurization simultaneously. This merger reduces the number of separate units required while maintaining conversion efficiency, directly addressing the contradiction between productivity and device complexity
Solution Approach 2:
The processing unit is designed to perform multiple functions within a single reactor system: upgrading heavy ends, cracking hydrocarbons, removing sulfur, and producing chemical feeds. This multi-functionality eliminates the need for sequential specialized units, reducing overall process complexity while maintaining high conversion rates
2Productivity
If high pressure conditions (up to 200 barg) are employed in hydrocracking, then the conversion of heavy hydrocarbons is enhanced, but the equipment investment costs and operational complexity increase
Solution Approach 1:
The patent optimizes pressure parameters by operating at reduced pressures (1-10 barg) compared to conventional high-pressure hydrocracking (200 barg). This parameter change achieves acceptable conversion rates without requiring expensive high-pressure equipment, directly addressing the contradiction between productivity and ease of manufacture
Solution Approach 2:
The patent introduces localized catalyst beds with specific properties (bifunctional catalysts containing metal particles on acidic supports) at critical locations within the reactor to enhance conversion efficiency at lower pressures. This localized quality enhancement allows reduced pressure operation while maintaining conversion rates, resolving the contradiction between productivity and equipment cost
3Productivity
If conventional multi-step upgrading processes are used, then heavy ends are converted to chemical feeds, but large amounts of fuel are consumed for preheating at each stage
Solution Approach 1:
The patent merges multiple preheating stages into a single preheating step before the integrated processing unit. By eliminating intermediate preheating steps required by sequential units, the total fuel consumption for heating is significantly reduced while still achieving the necessary temperature for conversion
Solution Approach 2:
The continuous flow through the integrated unit allows heat to be retained and utilized more efficiently throughout the process, reducing the need for repeated heating cycles. The continuous operation maintains thermal energy within the system, minimizing fuel consumption while sustaining high conversion rates
4Productivity
If cracking processes are used to produce olefins and aromatics, then high value chemicals are obtained, but coke formation increases requiring additional handling
Solution Approach 1:
The patent uses catalysts as intermediaries that facilitate the cracking reaction while suppressing coke formation. The bifunctional catalysts (metal particles on acidic supports) mediate the conversion process to produce olefins and aromatics with minimal coking, directly addressing the contradiction between productivity and harmful factors
Solution Approach 2:
The patent converts the potential harm of coke formation into a benefit by using controlled catalytic cracking that produces desirable aromatic chemicals while minimizing unwanted coke. The process transforms what would be a waste product (coke) into valuable aromatic compounds, resolving the contradiction between productivity and harmful factors
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 method reduces the number of processing units, minimizes fuel consumption, and maximizes the production of high-value chemicals such as ethylene and propylene, achieving higher carbon efficiency and reducing coke formation.
Implementation Method 1
subjecting a mixture comprising (1) a feedstock of crude oil and/or heavy oil and/or residues, (2) water and/or steam, (3) hydrogen, (4) a solvent selective for dissolving asphaltene, in a processing unit, to conditions sufficient to convert at least some hydrocarbon molecules of the feedstock to molecules that have less carbon atoms than the at least some hydrocarbon molecules
Implementation Method 2
a solvent selective for dissolving asphaltene
Implementation Method 3
distilling, in the distillation column, the reactor unit effluent to produce: (1) a gas stream that comprises primarily C1 to C4 saturates, (2) a liquid product stream that comprises primarily saturates
Implementation Method 4
cracking the liquid stream to produce one or more of ethylene, propylene, butene, and benzene
Data Source
AI summary
Systems and methods for producing olefins and/or aromatics are disclosed. Methods disclosed includes thermal hydro-processing of crude oils and/or heavy oils and/or residues, in a thermal hydro-processing unit, to produce intermediate products, which can then be used to make valuable chemicals such as olefins and aromatics.