CA2398473C - Multi zone cracking furnace - Google Patents
Multi zone cracking furnace Download PDFInfo
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- CA2398473C CA2398473C CA002398473A CA2398473A CA2398473C CA 2398473 C CA2398473 C CA 2398473C CA 002398473 A CA002398473 A CA 002398473A CA 2398473 A CA2398473 A CA 2398473A CA 2398473 C CA2398473 C CA 2398473C
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- separate
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- furnace
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- 238000005336 cracking Methods 0.000 title claims abstract description 45
- 238000000034 method Methods 0.000 claims description 39
- 229930195733 hydrocarbon Natural products 0.000 claims description 21
- 150000002430 hydrocarbons Chemical class 0.000 claims description 21
- 239000004215 Carbon black (E152) Substances 0.000 claims description 15
- 150000001336 alkenes Chemical class 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 9
- 239000000919 ceramic Substances 0.000 claims description 7
- 239000003546 flue gas Substances 0.000 claims description 5
- 238000000197 pyrolysis Methods 0.000 claims description 5
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 4
- 238000004891 communication Methods 0.000 claims description 4
- 238000007599 discharging Methods 0.000 claims description 4
- 239000000835 fiber Substances 0.000 claims description 4
- 239000011449 brick Substances 0.000 claims description 3
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 8
- 238000006243 chemical reaction Methods 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 6
- OTMSDBZUPAUEDD-UHFFFAOYSA-N Ethane Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 description 4
- 239000000446 fuel Substances 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 239000001294 propane Substances 0.000 description 4
- 238000010791 quenching Methods 0.000 description 4
- 230000000171 quenching effect Effects 0.000 description 4
- 230000001276 controlling effect Effects 0.000 description 3
- 150000002500 ions Chemical class 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 239000010454 slate Substances 0.000 description 2
- 229920002994 synthetic fiber Polymers 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- 241000282898 Sus scrofa Species 0.000 description 1
- WYTGDNHDOZPMIW-RCBQFDQVSA-N alstonine Natural products C1=CC2=C3C=CC=CC3=NC2=C2N1C[C@H]1[C@H](C)OC=C(C(=O)OC)[C@H]1C2 WYTGDNHDOZPMIW-RCBQFDQVSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 238000004939 coking Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 238000001754 furnace pyrolysis Methods 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 238000004227 thermal cracking Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J6/00—Heat treatments such as Calcining; Fusing ; Pyrolysis
- B01J6/008—Pyrolysis reactions
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
- C10G9/14—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils in pipes or coils with or without auxiliary means, e.g. digesters, soaking drums, expansion means
- C10G9/18—Apparatus
- C10G9/20—Tube furnaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00049—Controlling or regulating processes
- B01J2219/00051—Controlling the temperature
- B01J2219/00074—Controlling the temperature by indirect heating or cooling employing heat exchange fluids
- B01J2219/00076—Controlling the temperature by indirect heating or cooling employing heat exchange fluids with heat exchange elements inside the reactor
- B01J2219/00083—Coils
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00049—Controlling or regulating processes
- B01J2219/00051—Controlling the temperature
- B01J2219/0015—Controlling the temperature by thermal insulation means
- B01J2219/00155—Controlling the temperature by thermal insulation means using insulating materials or refractories
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00049—Controlling or regulating processes
- B01J2219/00051—Controlling the temperature
- B01J2219/00157—Controlling the temperature by means of a burner
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S585/00—Chemistry of hydrocarbon compounds
- Y10S585/919—Apparatus considerations
- Y10S585/921—Apparatus considerations using recited apparatus structure
Landscapes
- Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
- Gasification And Melting Of Waste (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Chemical And Physical Treatments For Wood And The Like (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Vertical, Hearth, Or Arc Furnaces (AREA)
Abstract
An improved furnace (2) which provides for multizone (12, 14, 18, 20), separate and independent cracking is provided.
Description
MUIrTI ZONE CRACKING FURNACE
FIELD OP THE INVENTION
The present invention relates generally to an apparatus for thermally cracking a hydrocarbon feedstock. More particularly the present invention relates to an apparatus for providing improved operational flexibility of the furnace.
BACKGROUND OF THE PRESENT INVENTION
The petrochemical industry has long used hydrocarbon feedstocks for the production of valuable olefinic materials, such as ethylene and propylene. Ideally, commercial operations have been carried out using normally gaseous hydrocaxbons such as ethane and propane as the feedstock. As the lighter hydrocarbons have been consumed and the availability of the lighter hydrocarbons has decreased, the industry has more recently been required to crack.
heaviex hydrocarbons, such as naphthas and gas oils.
A typical process for the production of olefins from hydrocarbon feedstocks is the thermal cracking process. In this process, hydrocarbons undergo cracking at elevated temperatures to produce hydrocarbons containing from 1 to 4 carbon atoms, especially the corresponding olefins: Typically, the hydrocarbon to be cracked is delivered to a furnace comprised of both a convection and radiant heating zone. The hydrocarbon is initially preheated in the convection zone to a temperature below that at which significant reaction is initiated; and thereafter is delivered to the radiant zone where it is sub jected to intense heat from radiant burners. Examples of conventional furnaces and processes are shown in United States Patent No. 3,487,121 (Hallee), and United States Patent No. 5,147,511 (Woebcke).
Illustratively, in the prior art, process fired heaters are used to provide the requisite heat for the reaction. The feedstock flows through a plurality of coils within the fired heatex, the coils being arranged in a manner that enhances the heat transfer t.o the hydrocarbon flowing through the coils. The cracked effluent is then preferably quenched either directly or indirectly i=o terminate the reaction. In conventional coil pyrolysis, dilution steam is also employed to assist in reducing coke formation in the cracking coil.
In recent times, industry is requiring the building of larger plants which have increased capacity but which require .less numbers of reactors. Thus, there has developed a need in the art to provide larger furnaces which are also flexible enough to handle a 1.0 variety of different feedstocks to produce a variety of different olefin products. Because each different feedstock and desired product slate entails the use of different reaction c:onc~itions, primarily, reaction temperature and reaction residence time, none of tlne currently available furnace technologies are suitable.
1.'~ Previous attempts in the prior art to meet these increased capacity and flexibility requirements in a single furnace nave proved insufficient.
It would therefore represent a notable advance in the state of the art if a furnace were developed which solved the 20 problems of the prior art furnaces as described above.
SUMMARY OF THE PRESENT INVENTION
It is an object of the present invention to provide an improved apparatus and process having increased .flexib.i.lity for the pyrolysis cracking of hydrocarbons to olefins.
Accordingly, the present invention provides a furnace for cracking at least two separate and independent hydrocarbon feeds to produce olefins, said furnace comprising: (a) at least one fired radiant chamber, wherein said radiant chamber is divided into at 30 least two separate independent radiant zones by a fired radiant chamber dividing means; (b) at least one radiant burner in each said separate independent radiant zone of said fired radiant charriber; (cj a c:onvect..ion chamber in direct communication with each said fired radiant chamber; (d) a separate and independent process roil for each said separate independent variant zone for cracking each said separate and independent feedstock, wherein each said separate and independent process coil extends through at least a portion of said convection chamber and extends into one of said separate and independent radiant zones for separately and independently cracking said separate and independent feedstocks to olefins before exiting said furnace; (e) a flue for discharging flue gas located at the top of said convection chamber of said furnace; and (f) a means for independently controlling the radiant burner in each said separate independent radiant zone.
The present invention also provides furnace for a cracking at least four separate and independent hydrocarbon feeds to produrce olefins, said furnace comprising: (a) at least two fired 1C1 radiant chambers, wherein said radiant chamber is divided into at least two separate independent radiant zones by a fired radiant chamber dividing means; (b) at least one radiant burner in each said separate and independent radiant zones of said fired radiant chamber; (c) a convection chamber in direct communication with said -fired radiant chamber; (d) a separate and independent process coil for each said separate independent radiant zone, wherein each said process coil extends through at least a portion of said convect=ion chamber and extends into one of said separate and independent radiant zones for separately and independently cracking said separate and independent feedstock to olefins before exiting said furnace; (e) a flue for discharging flue gas located at the top of each said convection chamber of said furnace; and (f) a means for independently controlling the radiant burner in each said separate independent radiant zone.
?5 The present invention further provides an improved pyrolysis cracking furnace having a radiant cracking chamber wherein said improvement comprises dividing said radiant cracking chamber into at least two separate and independent radiant cracking zones by providing a dividing wall in said radiant cracking chamber to 3l7 separate said radiant cracking zones into at least two separate and independent radiant cracking zones, providing a separate and independent process coil for directing a separate and independent hydrocarbon feedstock through each said separate and independent radiant cracking zone, and separately and independently controlling 35 the temperature in each of said separate and independent radiant cracking zone to crack each said separate and independent hydror_arbon feedstock to olefins.
3a BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 depicts in schematic form an embodiment of the present invention.
FIGURE 2 illustrates a top cross sectional view of an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
The multi zone cracking furnace of the present irment.ion will be described in relation to the furnace of Figure I. which has four separate and independent cracking zones. However, it is to be understood that the present application is not limited in any way to this detailed description, and all obvious modifications wtnich this detailed description suggests to those of ordinary skill i_n the art are also contemplated by the present application and the appended claims.
Referring to Figures 1 and 2, there is a shown a multizone pyrolysis furnace 2 of the present invention. As best seen in Figure 7_, the furnace 2 is provided with a convection section 4, a first fired radiant chamber 6 and a second fired radiant chamber 8. The first fired radiant chamber 6 is provided with a dividing wall 10 to divide the first radiant chamber 6 into a first separate independent radiant zone 12 and a second separate independent radiant zone 14. The second fired radiant chamber 8 is provided with a dividing wall 16 to divide the second radiant chamber 8 into a third separate independent radiant zone 18 and a fourth separate independent radiant zone 20.
In the embodiment of Figures 1 and 2 the dividing walls 10 and 16 divide their respective radiant chambers into substantially equal area separate independent radiant zones.
FIELD OP THE INVENTION
The present invention relates generally to an apparatus for thermally cracking a hydrocarbon feedstock. More particularly the present invention relates to an apparatus for providing improved operational flexibility of the furnace.
BACKGROUND OF THE PRESENT INVENTION
The petrochemical industry has long used hydrocarbon feedstocks for the production of valuable olefinic materials, such as ethylene and propylene. Ideally, commercial operations have been carried out using normally gaseous hydrocaxbons such as ethane and propane as the feedstock. As the lighter hydrocarbons have been consumed and the availability of the lighter hydrocarbons has decreased, the industry has more recently been required to crack.
heaviex hydrocarbons, such as naphthas and gas oils.
A typical process for the production of olefins from hydrocarbon feedstocks is the thermal cracking process. In this process, hydrocarbons undergo cracking at elevated temperatures to produce hydrocarbons containing from 1 to 4 carbon atoms, especially the corresponding olefins: Typically, the hydrocarbon to be cracked is delivered to a furnace comprised of both a convection and radiant heating zone. The hydrocarbon is initially preheated in the convection zone to a temperature below that at which significant reaction is initiated; and thereafter is delivered to the radiant zone where it is sub jected to intense heat from radiant burners. Examples of conventional furnaces and processes are shown in United States Patent No. 3,487,121 (Hallee), and United States Patent No. 5,147,511 (Woebcke).
Illustratively, in the prior art, process fired heaters are used to provide the requisite heat for the reaction. The feedstock flows through a plurality of coils within the fired heatex, the coils being arranged in a manner that enhances the heat transfer t.o the hydrocarbon flowing through the coils. The cracked effluent is then preferably quenched either directly or indirectly i=o terminate the reaction. In conventional coil pyrolysis, dilution steam is also employed to assist in reducing coke formation in the cracking coil.
In recent times, industry is requiring the building of larger plants which have increased capacity but which require .less numbers of reactors. Thus, there has developed a need in the art to provide larger furnaces which are also flexible enough to handle a 1.0 variety of different feedstocks to produce a variety of different olefin products. Because each different feedstock and desired product slate entails the use of different reaction c:onc~itions, primarily, reaction temperature and reaction residence time, none of tlne currently available furnace technologies are suitable.
1.'~ Previous attempts in the prior art to meet these increased capacity and flexibility requirements in a single furnace nave proved insufficient.
It would therefore represent a notable advance in the state of the art if a furnace were developed which solved the 20 problems of the prior art furnaces as described above.
SUMMARY OF THE PRESENT INVENTION
It is an object of the present invention to provide an improved apparatus and process having increased .flexib.i.lity for the pyrolysis cracking of hydrocarbons to olefins.
Accordingly, the present invention provides a furnace for cracking at least two separate and independent hydrocarbon feeds to produce olefins, said furnace comprising: (a) at least one fired radiant chamber, wherein said radiant chamber is divided into at 30 least two separate independent radiant zones by a fired radiant chamber dividing means; (b) at least one radiant burner in each said separate independent radiant zone of said fired radiant charriber; (cj a c:onvect..ion chamber in direct communication with each said fired radiant chamber; (d) a separate and independent process roil for each said separate independent variant zone for cracking each said separate and independent feedstock, wherein each said separate and independent process coil extends through at least a portion of said convection chamber and extends into one of said separate and independent radiant zones for separately and independently cracking said separate and independent feedstocks to olefins before exiting said furnace; (e) a flue for discharging flue gas located at the top of said convection chamber of said furnace; and (f) a means for independently controlling the radiant burner in each said separate independent radiant zone.
The present invention also provides furnace for a cracking at least four separate and independent hydrocarbon feeds to produrce olefins, said furnace comprising: (a) at least two fired 1C1 radiant chambers, wherein said radiant chamber is divided into at least two separate independent radiant zones by a fired radiant chamber dividing means; (b) at least one radiant burner in each said separate and independent radiant zones of said fired radiant chamber; (c) a convection chamber in direct communication with said -fired radiant chamber; (d) a separate and independent process coil for each said separate independent radiant zone, wherein each said process coil extends through at least a portion of said convect=ion chamber and extends into one of said separate and independent radiant zones for separately and independently cracking said separate and independent feedstock to olefins before exiting said furnace; (e) a flue for discharging flue gas located at the top of each said convection chamber of said furnace; and (f) a means for independently controlling the radiant burner in each said separate independent radiant zone.
?5 The present invention further provides an improved pyrolysis cracking furnace having a radiant cracking chamber wherein said improvement comprises dividing said radiant cracking chamber into at least two separate and independent radiant cracking zones by providing a dividing wall in said radiant cracking chamber to 3l7 separate said radiant cracking zones into at least two separate and independent radiant cracking zones, providing a separate and independent process coil for directing a separate and independent hydrocarbon feedstock through each said separate and independent radiant cracking zone, and separately and independently controlling 35 the temperature in each of said separate and independent radiant cracking zone to crack each said separate and independent hydror_arbon feedstock to olefins.
3a BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 depicts in schematic form an embodiment of the present invention.
FIGURE 2 illustrates a top cross sectional view of an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
The multi zone cracking furnace of the present irment.ion will be described in relation to the furnace of Figure I. which has four separate and independent cracking zones. However, it is to be understood that the present application is not limited in any way to this detailed description, and all obvious modifications wtnich this detailed description suggests to those of ordinary skill i_n the art are also contemplated by the present application and the appended claims.
Referring to Figures 1 and 2, there is a shown a multizone pyrolysis furnace 2 of the present invention. As best seen in Figure 7_, the furnace 2 is provided with a convection section 4, a first fired radiant chamber 6 and a second fired radiant chamber 8. The first fired radiant chamber 6 is provided with a dividing wall 10 to divide the first radiant chamber 6 into a first separate independent radiant zone 12 and a second separate independent radiant zone 14. The second fired radiant chamber 8 is provided with a dividing wall 16 to divide the second radiant chamber 8 into a third separate independent radiant zone 18 and a fourth separate independent radiant zone 20.
In the embodiment of Figures 1 and 2 the dividing walls 10 and 16 divide their respective radiant chambers into substantially equal area separate independent radiant zones.
However, it will be appreciated by those of ordinary skill in the art that the dividing wall may be located in the chamber to provide unequal area separate independent radiant zones. Additionally, moxe than one dividing wall, or any combination of number of dividing walls, may be employed in the radiant chambers of the furnace. For example, in the first radiant chamber, two dividing walls could be employed to divide the first radiant chamber into three equal area independent radiant zones, and in the second radiant chamber, three dividing walls could be employed to divide the second radiant chamber into four unegual independent radiant zones.
The dividing wall can be made only of a material which can withstand the temperatures in the radiant zone of the reactor, which can exceed temperatures of 2200°F. Accordingly, the dividing wall may be comprised of conventional fire brick. The dividing wall may also be comprised of a cloth-type material known as Nextel or may be a curtain made of this material, alone or in combination with a ceramic fiber material. In this type of embodiment the curtain is hung from rod supports. Other materials which provide similar thermal properties may be used.
Nextel is a tradename of the 3M Company for a family of ceramic fiber textile products. Nextel fibres are made from a synthetic precursor, not molten refractory oxides as are typically the case with ceramics. The synthetic fiber is formed in a continuous length to a controlled diameter and are then pyrolyzed to convert the synthetic materials into a ceramic. The continuous filiament ceramic fibers are spun into yarns and roving which can then be used to weave, braid, 3cnit or twist a variety of textile product forms, including a fabric for the curtains of the present invention. Preferred for use in the present invention is Nextel 312 which is composed of alumina/silica/boria. Also contemplated for use herein is Nexte~. 440.
It is important to the practice of the present invention that the dividing wall be constructed so that the conditions in one of the separate independent radiant zones do not substantially effect the conditions in an adjacent separate independent radiant zone. In this manner, the conditions in each adjacent radiant zone can be independently and separately controlled by adjustment of the radiant burners along the wall and/or floor of the zone as described hereinbelow.
Returning to Figure 1, the furnace 2 can be seen to be comprised of outer walls 22, centrally disposed walls 24, a roof 26, floors 28 and a chamber separating floor 30. Conventional wall burners 32 are arranged in an array along the outer walls 22 and centrally disposed walls 24. Additional conventional floor burners 34 are arranged in an array along the floors 28. The burners 32 and 34 may be supplied in conventional manner with natural gas or other combustible gas or finely dispersed fuels through headers, manifolds or individual piges leading to each burner which are not shown. The particular type of radiant heat burner and the details associated therewith need not be described herein since they axe well known and are conventional in the art. Any type of radiant heat burner can be used which provides substantially all of the heat by radiation. Important to the present invention is that each burner or array of burners in each independent radiant zone be separately and independently controlled, such as by regulating the amount of fuel supplied to the radiant burners. In this manner, the cracking temperature in each separate and independent radiant zone may be separately and independently controlled.
The furnace is also provided with a flue 36 fox removing flue gases from the burners in a line 38.
The furnace 2 of Figure 1 is also provided with four process coils . The first process coil 40 is preheated in exchanger 42 in the convection chamber 4 and then proceeds through into the first separate independent radiant zone 12. The second process coil 44 is preheated in exchanger 46 in the convection chamber 4 and then proceeds through the second independent radiant zone 14.
The third process coil 48 is preheated in exchanger 50 and then proceeds through the third independent radiant zone 18. The fourth process coil 52 is preheated in exchanger 52 and then proceeds through the fourth independent radiant zone 20. In Figure 2, for example, each radiant of the four radiant zones 12, 14, 18 and 20 is provided with two process coils, 40A, 40B, 44A, 44B, 48A, 48B, 52A and 52B, respectively.
Each of the process coils can independently be of separate lengths and/or configurations. Generally, the tubes are disposed vertically in the independent radiant zones, and are often of serpentine configurations. Other process coil configurations known to those skilled in the art are also contemplated for use herein. The coils may be of any length desired and generally have one portion proceeding downward into the independent radiant zone, a u-turn connecting zone, and one portion proceeding upward out of the independent radiant zone. Depending on the amount of product desired, a particular independent radiant zone can have a coil configuration designed to contain as many coils as necessary to obtain the desired capacity. For example, an independent radiant zone may be provided with from 1 to about 20 or more coil assemblies.
Each of the coils from the independent radiant heating zones then exit the furnace 2. Preferably, the process coils are grovided with a quenching apparatus for rapid quenching of the effluent product gases. Any of the quenching apparatuses known to those skilled in the art may be employed in the practice of the present invention. See, e.g., Woebcke et al., United States Patent No. 5,427,655. Additionally, it is contemplated by the present invention that each coil can be provided with its own quenching apparatus or the effluents from the process coils may be combined in any configuration and then quenched.
In an exemplary process employing the present invention, a first feed stream of ethane at a temperature of about 70°F to about 80°F is fed into coil 40 which is preheated in exchanger 42 in convection section 4, wherein it is heated to a temperature in the range of from about 1100°F to about 1200°F.
During the preheating step, depending on the boiling range of the feedstock the feed may be partially or completely vaporized. Also, in processes where steam is used, steam is added to the feed prior to the feed being introduced into the radiant zone. For example, the steam can be added at points in the preheat section, preferably where the feed is at Least 70% vaporized. The steam when added in this manner acts to completely vaporize the feed by reducing the hydrocarbon partial pressure.. The steam also functions to maintain low hydrocarbon partial pressure in the radiant zone for improved cracking efficiency and reduced coking.
Again, in each of the process coils, differing amounts of steam may be added to each of the coils depending upon the desired cracking to be performed in the process coils, 1.e., the type of feedstock and the desired product slate.
The coil 40 then proceeds into the first separate and independent radiant zone 12 wherein it is heated by radiant heat supplied from the radiant burners 32 and 34 along the walls and floor of the first separate and independent radiant zone I2.
Typically, an ethane feedstock will be cracked at a temperature ranging from about 780°C to about 1000°C for a residence time of from about O.Oi seconds to about 0.08 seconds.
Independently, but concurrently. process coil 44 is provided with a propane feedstock at a temperature of from about 70°F to about 80°F and is preheated in the convection zone 4 in exchanger 50 to a temperature in the range of from about 1100°F to about 1200°F. The process coil 44 then proceeds into the second separate and independent radiant zone wherein it is heated by radiant heat supplied from the radiant burners 32 and 34 along the walls and floor of the second separate and independent radiant zone i4. Typically, a propane feedstock will be cracked at a temperature ranging from about 780°C to about 1000°C for a residence time of from about O.D1 seconds to about 0.08 seconds.
Although both first and second radiant heating zones 12 and 14 are located in the same radiant chamber 6, the temperature in each zone may be separately controlled due to the provision of dividing wall 10 and the control of the amount of fuel burnt in the radiant burners of the radiant heating zone. Thus, two different WO 01155280 PC'T/US01I02443 feedstocks may be cracked in the same radiant chamber at separate and independent conditions, thereby allowing impxoved flexibility in the cracking operation. Of course, if desired, both process coils 40 and 44 could be provided with the same feedstock and cracked at substantially the same conditions.
A third feed stream of naphtha at a temperature of about 70°F to about 80°F is fed into coil 48 which is preheated in exchanger 50 in convection section 4, wherein it is heated to a temperature in the range of from about 1100°F to about 1200°F.
The coil 48 then proceeds into the third separate and independent radiant zone 18 wherein it is heated by radiant heat supplied from the radiant burners 32 and 34 along the walls and floor of the third separate and independent radiant zone 18. Typically, a naphtha feedstock will be cracked at a temperature ranging from about 780°C to about 1000°C for a residence time of from about 0.01 seconds to about 0.08 seconds.
Independently, but concurrently, process coil 5Z is provided with a vacuum gas oil (VGO) feedstock at a temperature of from about 70°F to about 80°F and is preheated in the convection zone 4 in exchanger S4 to a temperature in the range of from about 1100°F to about 1200°F. The process coil 52 then proceeds into the fourth separate and independent radiant zone 20 wherein it is heated by radiant heat supplied from the radiant burners 32 and 34 along the walls and floor of the second separate and independent radiant zone 20. Typically, a VGO feedstock will be cracked at a temperature ranging from about 780°C to about 1000°C for a residence time of from about 0.01 seconds to about 0.08 seconds.
Although both third and fourth radiant heating zones 18 and 20 are located in the same radiant chamber 8, the temperature in~.each zone may be separately controlled due to the provision of dividing wall 16 and the control of the amount of fuel burnt in the radiant burners of the radiant heating zone. Thus, two different feedstocks may be cracked in the same radiant chamber at separate and independent conditions, thereby allowing improved flexibility in the cracking operation. Of course, if desired, both process coils 48 and 52 could be provided with the same feedstock, or could be provided with a similar feedstock as being cracked in process coils 40 and/or 44 and cracked at substantially the same conditions.
Alternatively, where the full capacity of the furnace 2 is not required, one or more of the separate and independent radiant zones may be left idle by use of steam in the coil without effecting the cracking processes proceeding in the radiant zones in use. This further provides improved flexibility to the cracking apparatus of the present invention.
Many variations of the present invention will suggest themselves to those skilled in the art in light of the above-detailed description. For example, although the process of the present invention has been exemplified with ethane, propane, naphtha and VGO feedstocks, other feedstocks known to be used as feedstocks in radiant furnace pyrolysis cracking can also be employed within the practice of the present invention. All such obvious modifications are within the full intended scope of the appended claims.
The dividing wall can be made only of a material which can withstand the temperatures in the radiant zone of the reactor, which can exceed temperatures of 2200°F. Accordingly, the dividing wall may be comprised of conventional fire brick. The dividing wall may also be comprised of a cloth-type material known as Nextel or may be a curtain made of this material, alone or in combination with a ceramic fiber material. In this type of embodiment the curtain is hung from rod supports. Other materials which provide similar thermal properties may be used.
Nextel is a tradename of the 3M Company for a family of ceramic fiber textile products. Nextel fibres are made from a synthetic precursor, not molten refractory oxides as are typically the case with ceramics. The synthetic fiber is formed in a continuous length to a controlled diameter and are then pyrolyzed to convert the synthetic materials into a ceramic. The continuous filiament ceramic fibers are spun into yarns and roving which can then be used to weave, braid, 3cnit or twist a variety of textile product forms, including a fabric for the curtains of the present invention. Preferred for use in the present invention is Nextel 312 which is composed of alumina/silica/boria. Also contemplated for use herein is Nexte~. 440.
It is important to the practice of the present invention that the dividing wall be constructed so that the conditions in one of the separate independent radiant zones do not substantially effect the conditions in an adjacent separate independent radiant zone. In this manner, the conditions in each adjacent radiant zone can be independently and separately controlled by adjustment of the radiant burners along the wall and/or floor of the zone as described hereinbelow.
Returning to Figure 1, the furnace 2 can be seen to be comprised of outer walls 22, centrally disposed walls 24, a roof 26, floors 28 and a chamber separating floor 30. Conventional wall burners 32 are arranged in an array along the outer walls 22 and centrally disposed walls 24. Additional conventional floor burners 34 are arranged in an array along the floors 28. The burners 32 and 34 may be supplied in conventional manner with natural gas or other combustible gas or finely dispersed fuels through headers, manifolds or individual piges leading to each burner which are not shown. The particular type of radiant heat burner and the details associated therewith need not be described herein since they axe well known and are conventional in the art. Any type of radiant heat burner can be used which provides substantially all of the heat by radiation. Important to the present invention is that each burner or array of burners in each independent radiant zone be separately and independently controlled, such as by regulating the amount of fuel supplied to the radiant burners. In this manner, the cracking temperature in each separate and independent radiant zone may be separately and independently controlled.
The furnace is also provided with a flue 36 fox removing flue gases from the burners in a line 38.
The furnace 2 of Figure 1 is also provided with four process coils . The first process coil 40 is preheated in exchanger 42 in the convection chamber 4 and then proceeds through into the first separate independent radiant zone 12. The second process coil 44 is preheated in exchanger 46 in the convection chamber 4 and then proceeds through the second independent radiant zone 14.
The third process coil 48 is preheated in exchanger 50 and then proceeds through the third independent radiant zone 18. The fourth process coil 52 is preheated in exchanger 52 and then proceeds through the fourth independent radiant zone 20. In Figure 2, for example, each radiant of the four radiant zones 12, 14, 18 and 20 is provided with two process coils, 40A, 40B, 44A, 44B, 48A, 48B, 52A and 52B, respectively.
Each of the process coils can independently be of separate lengths and/or configurations. Generally, the tubes are disposed vertically in the independent radiant zones, and are often of serpentine configurations. Other process coil configurations known to those skilled in the art are also contemplated for use herein. The coils may be of any length desired and generally have one portion proceeding downward into the independent radiant zone, a u-turn connecting zone, and one portion proceeding upward out of the independent radiant zone. Depending on the amount of product desired, a particular independent radiant zone can have a coil configuration designed to contain as many coils as necessary to obtain the desired capacity. For example, an independent radiant zone may be provided with from 1 to about 20 or more coil assemblies.
Each of the coils from the independent radiant heating zones then exit the furnace 2. Preferably, the process coils are grovided with a quenching apparatus for rapid quenching of the effluent product gases. Any of the quenching apparatuses known to those skilled in the art may be employed in the practice of the present invention. See, e.g., Woebcke et al., United States Patent No. 5,427,655. Additionally, it is contemplated by the present invention that each coil can be provided with its own quenching apparatus or the effluents from the process coils may be combined in any configuration and then quenched.
In an exemplary process employing the present invention, a first feed stream of ethane at a temperature of about 70°F to about 80°F is fed into coil 40 which is preheated in exchanger 42 in convection section 4, wherein it is heated to a temperature in the range of from about 1100°F to about 1200°F.
During the preheating step, depending on the boiling range of the feedstock the feed may be partially or completely vaporized. Also, in processes where steam is used, steam is added to the feed prior to the feed being introduced into the radiant zone. For example, the steam can be added at points in the preheat section, preferably where the feed is at Least 70% vaporized. The steam when added in this manner acts to completely vaporize the feed by reducing the hydrocarbon partial pressure.. The steam also functions to maintain low hydrocarbon partial pressure in the radiant zone for improved cracking efficiency and reduced coking.
Again, in each of the process coils, differing amounts of steam may be added to each of the coils depending upon the desired cracking to be performed in the process coils, 1.e., the type of feedstock and the desired product slate.
The coil 40 then proceeds into the first separate and independent radiant zone 12 wherein it is heated by radiant heat supplied from the radiant burners 32 and 34 along the walls and floor of the first separate and independent radiant zone I2.
Typically, an ethane feedstock will be cracked at a temperature ranging from about 780°C to about 1000°C for a residence time of from about O.Oi seconds to about 0.08 seconds.
Independently, but concurrently. process coil 44 is provided with a propane feedstock at a temperature of from about 70°F to about 80°F and is preheated in the convection zone 4 in exchanger 50 to a temperature in the range of from about 1100°F to about 1200°F. The process coil 44 then proceeds into the second separate and independent radiant zone wherein it is heated by radiant heat supplied from the radiant burners 32 and 34 along the walls and floor of the second separate and independent radiant zone i4. Typically, a propane feedstock will be cracked at a temperature ranging from about 780°C to about 1000°C for a residence time of from about O.D1 seconds to about 0.08 seconds.
Although both first and second radiant heating zones 12 and 14 are located in the same radiant chamber 6, the temperature in each zone may be separately controlled due to the provision of dividing wall 10 and the control of the amount of fuel burnt in the radiant burners of the radiant heating zone. Thus, two different WO 01155280 PC'T/US01I02443 feedstocks may be cracked in the same radiant chamber at separate and independent conditions, thereby allowing impxoved flexibility in the cracking operation. Of course, if desired, both process coils 40 and 44 could be provided with the same feedstock and cracked at substantially the same conditions.
A third feed stream of naphtha at a temperature of about 70°F to about 80°F is fed into coil 48 which is preheated in exchanger 50 in convection section 4, wherein it is heated to a temperature in the range of from about 1100°F to about 1200°F.
The coil 48 then proceeds into the third separate and independent radiant zone 18 wherein it is heated by radiant heat supplied from the radiant burners 32 and 34 along the walls and floor of the third separate and independent radiant zone 18. Typically, a naphtha feedstock will be cracked at a temperature ranging from about 780°C to about 1000°C for a residence time of from about 0.01 seconds to about 0.08 seconds.
Independently, but concurrently, process coil 5Z is provided with a vacuum gas oil (VGO) feedstock at a temperature of from about 70°F to about 80°F and is preheated in the convection zone 4 in exchanger S4 to a temperature in the range of from about 1100°F to about 1200°F. The process coil 52 then proceeds into the fourth separate and independent radiant zone 20 wherein it is heated by radiant heat supplied from the radiant burners 32 and 34 along the walls and floor of the second separate and independent radiant zone 20. Typically, a VGO feedstock will be cracked at a temperature ranging from about 780°C to about 1000°C for a residence time of from about 0.01 seconds to about 0.08 seconds.
Although both third and fourth radiant heating zones 18 and 20 are located in the same radiant chamber 8, the temperature in~.each zone may be separately controlled due to the provision of dividing wall 16 and the control of the amount of fuel burnt in the radiant burners of the radiant heating zone. Thus, two different feedstocks may be cracked in the same radiant chamber at separate and independent conditions, thereby allowing improved flexibility in the cracking operation. Of course, if desired, both process coils 48 and 52 could be provided with the same feedstock, or could be provided with a similar feedstock as being cracked in process coils 40 and/or 44 and cracked at substantially the same conditions.
Alternatively, where the full capacity of the furnace 2 is not required, one or more of the separate and independent radiant zones may be left idle by use of steam in the coil without effecting the cracking processes proceeding in the radiant zones in use. This further provides improved flexibility to the cracking apparatus of the present invention.
Many variations of the present invention will suggest themselves to those skilled in the art in light of the above-detailed description. For example, although the process of the present invention has been exemplified with ethane, propane, naphtha and VGO feedstocks, other feedstocks known to be used as feedstocks in radiant furnace pyrolysis cracking can also be employed within the practice of the present invention. All such obvious modifications are within the full intended scope of the appended claims.
Claims (12)
1. A furnace for cracking at least two separate and independent hydrocarbon feeds to produce olefins, said furnace comprising:
(a) at least one fired radiant chamber, wherein said radiant chamber is divided into at least two separate independent radiant zones by a fired radiant chamber dividing means;
(b) at least one radiant burner in each said separate independent radiant zone of said fired radiant chamber;
(c) a convection chamber in direct communication with each said fired radiant chamber;
(d) a separate and independent process coil for each said separate independent variant zone for cracking each said separate and independent feedstock, wherein each said separate and independent process coil extends through at least a portion of said convection chamber and extends into one of said separate and independent radiant zones for separately and independently cracking said separate and independent feedstocks to olefins before exiting said furnace;
(e) a flue for discharging flue gas located at the top of said convection chamber of said furnace; and (f) a means for independently controlling the radiant burner in each said separate independent radiant zone.
(a) at least one fired radiant chamber, wherein said radiant chamber is divided into at least two separate independent radiant zones by a fired radiant chamber dividing means;
(b) at least one radiant burner in each said separate independent radiant zone of said fired radiant chamber;
(c) a convection chamber in direct communication with each said fired radiant chamber;
(d) a separate and independent process coil for each said separate independent variant zone for cracking each said separate and independent feedstock, wherein each said separate and independent process coil extends through at least a portion of said convection chamber and extends into one of said separate and independent radiant zones for separately and independently cracking said separate and independent feedstocks to olefins before exiting said furnace;
(e) a flue for discharging flue gas located at the top of said convection chamber of said furnace; and (f) a means for independently controlling the radiant burner in each said separate independent radiant zone.
2. A furnace for cracking at least four separate and independent hydrocarbon feeds to produce olefins, said furnace comprising:
(a) at least two fired radiant chambers, wherein said radiant chamber is divided into at least two separate independent radiant zones by a fired radiant chamber dividing means;
(b) at least one radiant burner in each said separate and independent radiant zones of said fired radiant chamber;
(c) a convection chamber in direct communication with said fired radiant chamber;
(d) a separate and independent process coil for each said separate independent radiant zone, wherein each said process coil extends through at least a portion of said convection chamber and extends into one of said separate and independent radiant zones for separately and independently cracking said separate and independent feedstock to olefins before exiting said furnace;
(e) a flue for discharging flue gas located at the top of each said convection chamber of said furnace; and (f) a means for independently controlling the radiant burner in each said separate independent radiant zone.
(a) at least two fired radiant chambers, wherein said radiant chamber is divided into at least two separate independent radiant zones by a fired radiant chamber dividing means;
(b) at least one radiant burner in each said separate and independent radiant zones of said fired radiant chamber;
(c) a convection chamber in direct communication with said fired radiant chamber;
(d) a separate and independent process coil for each said separate independent radiant zone, wherein each said process coil extends through at least a portion of said convection chamber and extends into one of said separate and independent radiant zones for separately and independently cracking said separate and independent feedstock to olefins before exiting said furnace;
(e) a flue for discharging flue gas located at the top of each said convection chamber of said furnace; and (f) a means for independently controlling the radiant burner in each said separate independent radiant zone.
3. A furnace as defined in Claim 1 wherein said fired radiant chamber is divided into two separate independent radiant zones having substantially the same area.
4. A furnace as defined in Claim 1 wherein said fired radiant chamber is divided into two separate independent radiant zones which have substantially different area.
5. A furnace as defined in Claim 1 wherein said fired radiant chamber dividing means is a brick wall.
6. A furnace as defined in Claim 1 wherein said fired radiant chamber dividing means is a curtain of Nextel.TM. material.
7. A furnace as defined in Claim 1 wherein said fired radiant chamber means is a combination of a curtain of Nextel.TM. material and ceramic fiber wall.
8. A furnace as defined in Claim 1 wherein said means for independently controlling the radiant burners in each said separate independent radiant zone comprises a means for controlling the temperature of each said separate independent radiant zone independently.
9. An improved pyrolysis cracking furnace having a radiant cracking chamber wherein said improvement comprises dividing said radiant cracking chamber into at least two separate and independent radiant cracking zones by providing a dividing wall in said radiant cracking chamber to separate said radiant cracking zones into at least two separate and independent radiant cracking zones, providing a separate and independent process coil for directing a separate and independent hydrocarbon feedstock through each said separate and independent radiant cracking zone, and separately and independently controlling the temperature in each of said separate and independent radiant cracking zone to crack each said separate and independent hydrocarbon feedstock to olefins.
10. An improved furnace as defined in Claim 9 wherein said fired radiant chamber dividing means is a brick wall.
11. A furnace as defined in Claim 9 wherein said fired radiant chamber dividing means is a curtain of Nextel.TM. material.
12. A furnace as defined in Claim 9 wherein said fired radiant chamber dividing means is a combination of a curtain of Nextel.TM. material and ceramic fiber wall.
Applications Claiming Priority (3)
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|---|---|---|---|
| US49335000A | 2000-01-28 | 2000-01-28 | |
| US09/493,350 | 2000-01-28 | ||
| PCT/US2001/002443 WO2001055280A1 (en) | 2000-01-28 | 2001-01-22 | Multi zone cracking furnace |
Publications (2)
| Publication Number | Publication Date |
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| CA2398473A1 CA2398473A1 (en) | 2001-08-02 |
| CA2398473C true CA2398473C (en) | 2007-01-09 |
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| CA002398473A Expired - Lifetime CA2398473C (en) | 2000-01-28 | 2001-01-22 | Multi zone cracking furnace |
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| EP (1) | EP1252254B1 (en) |
| KR (1) | KR20030065301A (en) |
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| MX (1) | MXPA02007325A (en) |
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2001
- 2001-01-22 AU AU2001232962A patent/AU2001232962A1/en not_active Abandoned
- 2001-01-22 CA CA002398473A patent/CA2398473C/en not_active Expired - Lifetime
- 2001-01-22 EP EP01905043A patent/EP1252254B1/en not_active Expired - Lifetime
- 2001-01-22 WO PCT/US2001/002443 patent/WO2001055280A1/en not_active Application Discontinuation
- 2001-01-22 DE DE60133087T patent/DE60133087T2/en not_active Expired - Lifetime
- 2001-01-22 PT PT01905043T patent/PT1252254E/en unknown
- 2001-01-22 CN CNB018067158A patent/CN1250678C/en not_active Expired - Lifetime
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2007
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Effective date: 20210122 |