Vaporization Unit for Acid-Containing Hydrocarbon Feedstock Processing
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Solution Overview
Problem
The olefin production industry faces challenges in processing organic acid-containing feedstocks, particularly crude oils with high Total Acid Numbers (TAN), as existing technologies struggle to effectively reduce acid content and convert these feedstocks into additional thermal cracking feed, due to the corrosive nature of naphthenic acids which limits processing temperatures.
Innovation Solution
A process combining a vaporization unit with at least one thermal cracking furnace is employed to reduce organic acid content and generate additional cracking feed by vaporizing and mildly cracking organic acid-containing feedstocks, such as whole crude oil, condensate, and their fractions, using a vaporization unit in conjunction with a thermal cracking furnace, converting naphthenic acids into carbon monoxide, carbon dioxide, and lower molecular weight acids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal cracking is performed on high acid content feedstocks, then additional cracking feed is generated, but corrosion increases due to naphthenic acids
Solution Approach 1:
The patent applies preliminary action by pre-vaporizing the feedstock in a vaporization unit before it enters the thermal cracking furnace. This preliminary vaporization step converts naphthenic acids into volatile forms that can be removed in subsequent condensation and washing sections, reducing corrosion in the cracking furnace while still allowing the feedstock to undergo thermal cracking for olefin production
Solution Approach 2:
The patent converts the harmful naphthenic acids into beneficial volatile compounds through vaporization. The acids are vaporized, condensed, and washed to remove them from the feedstock before cracking, transforming the corrosive harmful factor into a removable volatile substance that protects the cracking furnace from corrosion
2Productivity
If processing temperature is increased to reduce acid content, then cracking efficiency improves, but corrosion resistance deteriorates
Solution Approach 1:
The patent performs preliminary vaporization at moderate temperatures before the high-temperature cracking zone. This preliminary step removes naphthenic acids at lower temperatures where corrosion is less severe, allowing the subsequent cracking to proceed at high temperatures without the same corrosion problems
Solution Approach 2:
The patent segments the processing into distinct zones: a vaporization unit for acid removal at moderate temperatures, followed by a thermal cracking furnace for olefin production at high temperatures. This segmentation allows each zone to operate at optimal temperatures for its specific function, protecting equipment from corrosion while maintaining cracking efficiency
3Object-affected harmful factors
If naphthenic acids are converted to CO and CO2, then corrosion is reduced, but additional processing steps are required
Solution Approach 1:
The patent merges the vaporization, condensation, and washing functions into an integrated vaporization unit that operates in conjunction with the cracking furnace. This combined approach removes naphthenic acids through vaporization and condensation while the cracking furnace simultaneously produces olefins, reducing the need for separate dedicated acid removal equipment
Solution Approach 2:
The vaporization unit serves multiple functions: it vaporizes naphthenic acids for removal, pre-heats the feedstock for cracking, and separates volatile acid compounds from the liquid feed. This multi-functionality reduces the need for separate dedicated equipment for each function
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 effectively reduces the organic acid content in feedstocks, minimizes corrosion, and generates additional thermal cracking feed, enhancing the processing of high TAN feeds by converting naphthenic acids into less corrosive products, thereby improving the operational efficiency and product yield in olefin production.
Implementation Method 1
a vaporization unit in combination with at least one thermal cracking furnace to generate additional cracking feed by way of the vaporization unit while reducing by way of the cracking operation the organic acid content originally present in those feedstocks
Implementation Method 2
Thermal cracking (pyrolysis) of hydrocarbons is a petrochemical process that is widely used to produce olefins such as ethylene, propylene, butenes, butadiene, and aromatics
Implementation Method 3
converting naphthenic acids into carbon monoxide, carbon dioxide, and lower molecular weight acids
Data Source
AI summary
A method for thermally cracking an organic acid containing hydrocarbonaceous feed wherein the feed is first processed in a vaporization step, followed by thermal cracking.