Crude to Chemicals Process Integrating Vacuum Residue Hydrocracking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current processes for converting crude oil to petrochemicals and fuel products are limited by the availability and quality of feedstocks, leading to high costs and energy intensiveness, with a need for improved methods that leverage economies of scale and offer higher value chemical production opportunities.
Innovation Solution
An integrated process involving atmospheric and vacuum distillation, hydroprocessing, and steam cracking to separate and convert crude oil into naphtha, diesel, and other fractions, which are then processed in hydroprocessing and steam cracking zones to produce petrochemicals like ethylene, propylene, and aromatics, optimizing feedstock utilization and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If steam pyrolysis is used to produce lower olefins and aromatics, then these basic chemical intermediates can be formed, but the process requires costly and energy-intensive operations with limited feedstock availability
Solution Approach 1:
The patent changes the operating parameters of the cracking process by using severe hydrocracking conditions (high temperature, high pressure, high severity) to convert heavy vacuum residue directly into light olefinic feeds suitable for steam cracking, eliminating the need for traditional naphtha feedstock and reducing energy consumption in feedstock preparation
Solution Approach 2:
The integrated process combines multiple functions into a unified system where the hydrocracker serves both as a conversion unit for vacuum residue and as a feedstock producer for the steam cracker, while the steam cracker simultaneously produces both chemical intermediates and fuel blends, achieving multi-functionality and economies of scale
2Quantity of substance
If heavy naphtha is used as feedstock for ethylene production, then feedstock supply is improved, but the lower paraffin and higher aromatics content makes it less suitable without upgrading
Solution Approach 1:
The patent applies severe hydrocracking parameters (temperature 350-450°C, pressure 90-200 atm, LHSV 0.5-2.0 hr⁻¹) to convert heavy naphtha and vacuum residue into light olefinic feeds with optimized paraffin content and reduced aromatics, producing feedstock quality suitable for ethylene production without requiring separate upgrading units
3Productivity
If vacuum residue is processed through conventional methods, then fuel products can be produced, but the process lacks integration with petrochemical production and misses higher value opportunities
Solution Approach 1:
The patent merges the hydrocracking and steam cracking processes into an integrated 'crude to chemicals' conversion system where vacuum residue is converted to light olefinic feeds that are directly fed to the steam cracker, combining fuel and chemical production pathways into a unified process that maximizes value from heavy feedstocks
Solution Approach 2:
The patent segments the vacuum residue conversion process into distinct functional zones within the hydrocracker (reaction zone, separation zone, fractionation zone) that produce different product streams (light olefinic feed, diesel blendstock, jet fuel blendstock) which can be selectively routed to meet both fuel and chemical production demands
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
The integrated process enhances the conversion of crude oil into valuable petrochemicals and fuels efficiently, improving economic viability by optimizing feedstock use and reducing energy consumption, thereby addressing the limitations of existing methods.
Implementation Method 1
an initial separation step to separate from a crude oil feed in an atmospheric distillation zone
Implementation Method 2
at least a fraction comprising straight run naphtha and lighter components
Implementation Method 3
A vacuum gas oil fraction is separated from the atmospheric residue fraction in a vacuum distillation zone
Implementation Method 4
In a distillate hydroprocessing ("DHP") zone, such as a diesel hydrotreater, at least a portion of the middle distillates are processed to produce a naphtha fraction and a diesel fuel fraction
Implementation Method 5
The vacuum gas oil fraction (and optionally all or a portion of an atmospheric gas oil fraction, or all or a portion of a heavy atmospheric gas oil fraction) is processed in a gas oil hydroprocessing zone
Implementation Method 6
Thermal cracking, or steam pyrolysis, is a major type of process for forming these materials, typically in the presence of steam, and in the absence of oxygen
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Process scheme configurations are disclosed that enable conversion of crude oil feeds with several processing units in an integrated manner into petrochemicals. The designs utilize minimum capital expenditures to prepare suitable feedstocks for the steam cracker complex. The integrated process for converting crude oil to petrochemical products including olefins and aromatics, and fuel products, includes mixed feed steam cracking and gas oil steam cracking. Feeds to the mixed feed steam cracker include one or more naphtha fractions from hydroprocessing zones within the battery limits, including vacuum residue hydrocracking, within the battery limits, recycle streams from the C3 and C4 olefins recovery steps, and raffinate from a pyrolysis gasoline aromatics extraction zone within the battery limits. Feeds to the gas oil steam cracker include gas oil range intermediates from the vacuum gas oil hydroprocessing zone and the vacuum residue hydrocracking zone.