WO2021025930A1 - Procédés et systèmes de valorisation d'une charge contenant des hydrocarbures - Google Patents

Procédés et systèmes de valorisation d'une charge contenant des hydrocarbures Download PDF

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Publication number
WO2021025930A1
WO2021025930A1 PCT/US2020/044137 US2020044137W WO2021025930A1 WO 2021025930 A1 WO2021025930 A1 WO 2021025930A1 US 2020044137 W US2020044137 W US 2020044137W WO 2021025930 A1 WO2021025930 A1 WO 2021025930A1
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Prior art keywords
particles
stream
hydrocarbon
pyrolysis
transition metal
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PCT/US2020/044137
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English (en)
Inventor
Michael F. Raterman
Mohsen N. Harandi
Paul F. Keusenkothen
David B. Spry
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Exxonmobil Chemical Patents Inc.
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Priority to US17/627,842 priority Critical patent/US20220275283A1/en
Publication of WO2021025930A1 publication Critical patent/WO2021025930A1/fr

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Classifications

    • 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
    • C10G9/28—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid material
    • C10G9/32—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid material according to the "fluidised-bed" technique
    • 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
    • C10G9/34—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts
    • C10G9/36—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts with heated gases or vapours
    • C10G9/38—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts with heated gases or vapours produced by partial combustion of the material to be cracked or by combustion of another hydrocarbon
    • 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
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10—Feedstock materials
    • C10G2300/107—Atmospheric residues having a boiling point of at least about 538 °C
    • 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
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10—Feedstock materials
    • C10G2300/1077—Vacuum residues
    • 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
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/40—Characteristics of the process deviating from typical ways of processing
    • C10G2300/4081—Recycling aspects
    • 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
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/80—Additives
    • 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
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/20—C2-C4 olefins

Definitions

  • This disclosure relates to processes and systems for upgrading a hydrocarbon- containing feed.
  • this disclosure relates to processes and systems for converting a hydrocarbon-containing feed by pyrolysis to produce various products, e.g., olefins and fuel oil products.
  • Steam cracking also referred to as pyrolysis
  • pyrolysis has long been used to crack various hydrocarbon-containing feeds into olefins, preferably light olefins such as ethylene, propylene, and butenes.
  • Conventional steam cracking utilizes a pyrolysis furnace (“steam cracker”) that has two main sections: a convection section and a radiant section.
  • the hydrocarbon-containing feed typically enters the convection section of the furnace as a liquid (except for light feedstocks that typically enter as a vapor) where the feedstock is typically heated and vaporized by indirect heat exchange with a hot flue gas from the radiant section and by direct contact with steam.
  • the vaporized feedstock and steam mixture is fed into the radiant section where the cracking takes place.
  • the resulting pyrolysis effluent, including olefins leaves the pyrolysis furnace for further downstream processing, including quenching.
  • liquid hydrocarbons however, still contain a substantial quantity of hydrocarbons which, if converted into higher- value lighter hydrocarbons such as olefins via cracking, would bring substantial additional value to the crude oil feed.
  • lighter hydrocarbons such as olefins via cracking
  • the large amount of non-volatiles in the low-cost heavy crude oil requires extensive and expensive processing.
  • the present inventors have devised a process and system for converting a hydrocarbon-containing feed by pyrolysis.
  • the process for converting a hydrocarbon-containing feed by pyrolysis can include (I) feeding the hydrocarbon-containing feed into a pyrolysis reaction zone and (II) feeding a plurality of fluidized particles having a first temperature into the pyrolysis reaction zone.
  • the first temperature can be sufficiently high to enable pyrolysis of at least a portion of the hydrocarbon-containing feed on contacting the particles.
  • the particles can include an oxide of a transition metal element capable of oxidizing molecular hydrogen (3 ⁇ 4) at the first temperature.
  • the process can also include (III) contacting at least a portion of the hydrocarbon-containing feed with the particles in the pyrolysis reaction zone to effect pyrolysis of at least a portion of the hydrocarbon-containing feed to produce a pyrolysis effluent that can include olefins, hydrogen, and the particles. At least a portion of the transition metal element in the particles in the pyrolysis effluent can be at a reduced state compared to the transition metal element in the particles fed into the pyrolysis reaction zone.
  • the process for converting a hydrocarbon-containing feed by pyrolysis can include (I) feeding the hydrocarbon-containing feed to a pyrolysis reaction zone and (II) feeding a plurality of fluidized particles having a first temperature into the pyrolysis reaction zone.
  • the hydrocarbon-containing feed can include a first transition metal element.
  • the first temperature can be sufficiently high to enable pyrolysis of at least a portion of the hydrocarbon-containing feed on contacting the particles.
  • the particles can include an oxide of a second transition metal element capable of oxidizing molecular hydrogen (3 ⁇ 4) at the first temperature.
  • the process can also include (III) contacting at least a portion of the hydrocarbon- containing feed with the particles in the pyrolysis reaction zone to effect pyrolysis of at least a portion of the hydrocarbon-containing feed to produce a pyrolysis effluent that can include olefins, hydrogen, and the particles.
  • a pyrolysis effluent can include olefins, hydrogen, and the particles.
  • At least a portion of the second transition metal element in the particles in the pyrolysis effluent can be at a reduced state compared to the transition metal element in the particles fed into the pyrolysis reaction zone.
  • At least a portion of the first transition metal element in the hydrocarbon-containing feed can deposit onto the particles.
  • the process can also include (IV) optionally steam stripping the pyrolysis effluent using a stripping steam stream, (V) obtaining from the pyrolysis effluent optionally admixed with the stripping steam stream a first hydrocarbon stream rich in hydrocarbons and a first particle stream rich in the particles, (VI) oxidizing and heating at least a portion of the particles in the first particle stream in a combustion zone such that at least a portion of the second transition metal element in the particles oxidizes to a higher oxidation state compared to the second transition metal element in the particles in the pyrolysis effluent, and (VII) feeding at least a portion of the heated and oxidized particles to the pyrolysis reaction zone as at least a portion of the plurality of fluidized particles fed into the pyrolysis reaction zone in step (II).
  • the system for converting a hydrocarbon-containing feed by pyrolysis can include (i) a pyrolysis reactor adapted for receiving the hydrocarbon-containing feed and a fluidized stream of particles having a first temperature, allowing at least a portion of the hydrocarbon-containing feed to contact the particles to effect pyrolysis of at least a portion of the hydrocarbon-containing feed, and discharging a pyrolysis effluent.
  • the first temperature can be sufficiently high to enable pyrolysis of at least a portion of the hydrocarbon- containing feed.
  • the particles can include an oxide of a transition metal capable of oxidizing molecular hydrogen (3 ⁇ 4) at the first temperature.
  • the system can also include (ii) a first separation vessel adapted for receiving the pyrolysis effluent, optionally receiving a stripping steam stream, separating the pyrolysis effluent to obtain a first hydrocarbon stream rich in hydrocarbons and a first particle stream rich in the particles, discharging the first hydrocarbon stream, and discharging the first particle stream.
  • a first separation vessel adapted for receiving the pyrolysis effluent, optionally receiving a stripping steam stream, separating the pyrolysis effluent to obtain a first hydrocarbon stream rich in hydrocarbons and a first particle stream rich in the particles, discharging the first hydrocarbon stream, and discharging the first particle stream.
  • the system can also include (iii) a combustion vessel adapted for receiving a stream of an oxidizing agent, receiving at least a portion of the first particle stream, optionally receiving a fuel stream, optionally combusting the fuel, combusting the particles, heating the particles, oxidizing the particles, and discharging a combustion zone effluent that can include the heated and oxidized particles and a flue gas.
  • the system can also include (iv) a second separation vessel adapted for receiving the combustion zone effluent, separating the combustion zone effluent to obtain a second particle stream rich in the particles and a first flue gas stream rich in the flue gas, discharging the second particle stream, and discharging the first flue gas stream.
  • the system can also include (v) a channel adapted for feeding at least a portion of the second particle stream to the pyrolysis reactor.
  • the system can also include (vi) a quenching section adapted for receiving the first hydrocarbon stream, receiving a stream of a quenching medium, and discharging a quenched mixture stream that can include the quenching medium and the first hydrocarbon stream.
  • the system can also include (vii) a third separation vessel that can include a cyclone.
  • the third separation vessel can be adapted for receiving the quenched mixture stream, separating the quenched mixture stream to obtain a third particle stream rich in the particles and a second hydrocarbon stream rich in hydrocarbons, discharging the third particle stream, and discharging the second hydrocarbon stream.
  • the system can also include (viii) a channel adapted for feeding at least a portion of the third particle stream to the first separation vessel or to the combustion vessel.
  • the Figure depicts an illustrative system for converting a hydrocarbon-containing feed by pyrolysis, according to one or more embodiments described.
  • a process is described as comprising at least one “step.” It should be understood that each step is an action or operation that may be carried out once or multiple times in the process, in a continuous or discontinuous fashion. Unless specified to the contrary or the context clearly indicates otherwise, multiple steps in a process may be conducted sequentially in the order as they are listed, with or without overlapping with one or more other steps, or in any other order, as the case may be. In addition, one or more or even all steps may be conducted simultaneously with regard to the same or different batch of material.
  • a second step may be carried out simultaneously with respect to an intermediate material resulting from treating the raw materials fed into the process at an earlier time in the first step.
  • the steps are conducted in the order described.
  • the indefinite article “a” or “an” shall mean “at least one” unless specified to the contrary or the context clearly indicates otherwise.
  • embodiments using “a pyrolysis reactor” include embodiments where one, two or more pyrolysis reactors are used, unless specified to the contrary or the context clearly indicates that only one pyrolysis reactor is used.
  • Crude as used herein means whole crude oil as it flows from a wellhead, a production field facility, a transportation facility, or other initial field processing facility, optionally including crude that has been processed by a step of desalting, treating, and/or other steps as may be necessary to render it acceptable for conventional distillation in a refinery. Crude, as used herein, is presumed to contain resid.
  • Crude fraction as used herein, means a hydrocarbon fraction obtained via the fractionation of crude.
  • resid refers to a bottoms cut of a crude distillation process that contains non-volatile components. Resids are complex mixtures of heavy petroleum compounds otherwise known in the art as residuum or residual. Atmospheric resid is the bottoms product produced from atmospheric distillation of crude where a typical endpoint of the heaviest distilled product is nominally 343 °C, and is referred to as 343 °C resid.
  • the term “nominally”, as used herein, means that reasonable experts may disagree on the exact cut point for these terms, but by no more than +/- 55.6°C preferably no more than +/- 27.8°C.
  • Vacuum resid is the bottoms product from a distillation column operated under vacuum where the heaviest distilled product can be nominally 566°C, and is referred to as 566°C resid.
  • non-volatile components refers to the fraction of a hydrocarbon-containing feed, e.g., a petroleum feed, having a nominal boiling point of at least 590°C, as measured by ASTM D6352-15 or D-2887-18.
  • Non-volatile components include coke precursors, which are large, condensable molecules that condense in the vapor and then form coke during pyrolysis of the hydrocarbon-containing feed.
  • hydrocarbon as used herein means (i) any compound consisting of hydrogen and carbon atoms or (ii) any mixture of two or more such compounds in (i).
  • Cn hydrocarbon where n is a positive integer, means (i) any hydrocarbon compound comprising carbon atom(s) in its molecule at the total number of n, or (ii) any mixture of two or more such hydrocarbon compounds in (i).
  • a C2 hydrocarbon can be ethane, ethylene, acetylene, or mixtures of at least two of these compounds at any proportion.
  • a “C2 to C3 hydrocarbon” or “C2-C3 hydrocarbon” can be any of ethane, ethylene, acetylene, propane, propene, propyne, propadiene, cyclopropane, and any mixtures of two or more thereof at any proportion between and among the components.
  • a “saturated C2-C3 hydrocarbon” can be ethane, propane, cyclopropane, or any mixture thereof of two or more thereof at any proportion.
  • a “Cn+ hydrocarbon” means (i) any hydrocarbon compound comprising carbon atom(s) in its molecule at the total number of at least n, or (ii) any mixture of two or more such hydrocarbon compounds in (i).
  • a “Cn- hydrocarbon” means (i) any hydrocarbon compound comprising carbon atoms in its molecule at the total number of at most n, or (ii) any mixture of two or more such hydrocarbon compounds in (i).
  • a “Cm hydrocarbon stream” means a hydrocarbon stream consisting essentially of Cm hydrocarbon(s).
  • a “Cm-Cn hydrocarbon stream” means a hydrocarbon stream consisting essentially of Cm-Cn hydrocarbon(s).
  • olefin product means a product that includes an olefin, preferably a product consisting essentially of an olefin.
  • An olefin product in the meaning of this disclosure can be, e.g., an ethylene stream, a propylene stream, a butylene stream, an ethylene/propylene mixture stream, and the like.
  • compositions, feed, effluent, product, or other stream comprises a given component at a concentration of at least 60 wt%, preferably at least 70 wt%, more preferably at least 80 wt%, more preferably at least 90 wt%, still more preferably at least 95 wt%, based on the total weight of the composition, feed, effluent, product, or other stream in question.
  • aromatic as used herein is to be understood in accordance with its art- recognized scope which includes alkyl substituted and unsubstituted mono- and polynuclear compounds.
  • X-rich when used in phrases such as “X-rich” or “rich in X” means, with respect to an outgoing stream obtained from a device, that the stream comprises material X at a concentration higher than in the feed material fed to the same device from which the stream is derived.
  • lean when used in phrases such as “X-lean” or “lean in X” means, with respect to an outgoing stream obtained from a device, that the stream comprises material X at a concentration lower than in the feed material fed to the same device from which the stream is derived.
  • channel and line are used interchangeably and mean any conduit configured or adapted for feeding, flowing, and/or discharging a gas, a liquid, and/or a fluidized solids feed into the conduit, through the conduit, and/or out of the conduit, respectively.
  • a composition can be fed into the conduit, flow through the conduit, and/or discharge from the conduit to move the composition from a first location to a second location.
  • Suitable conduits can be or can include, but are not limited to, pipes, hoses, ducts, tubes, and the like.
  • wt% means percentage by weight
  • vol% means percentage by volume
  • mol% means percentage by mole
  • ppm means parts per million
  • ppm wt and wppm are used interchangeably to mean parts per million on a weight basis. All concentrations herein are expressed on the basis of the total amount of the composition in question, unless specified otherwise. Thus, the concentrations of the various components of the “hydrocarbon-containing feed” are expressed based on the total weight of the hydrocarbon- containing feed. All ranges expressed herein should include both end points as two specific embodiments unless specified or indicated to the contrary.
  • a typical crude includes a mixture of hydrocarbons with varying carbon numbers and boiling points.
  • hydrocarbons with varying carbon numbers and boiling points.
  • naphtha gasoline, kerosene, distillate, and tar.
  • the hydrocarbon-containing feed can be, can include, or can be derived from petroleum, plastic, natural gas condensate, landfill gas (LFG), biogas, coal, biomass, biobased oils, rubber, or any mixture thereof.
  • LFG landfill gas
  • biogas biogas
  • coal coal
  • biomass biomass
  • biobased oils rubber
  • the hydrocarbon-containing feed can include a non-volatile component.
  • the petroleum can be or can include any crude or any mixture thereof, any crude fraction or any mixture thereof, or any mixture of any crude with any crude fraction.
  • the petroleum can be or can include: atmospheric resid, vacuum resid, steam cracked gas oil and residue, gas oil, heating oil, hydrocrackate, atmospheric pipestill bottoms, vacuum pipestill streams including bottoms, gas oil condensate, heavy non-virgin hydrocarbon stream from refineries, vacuum gas oil, heavy gas oil, naphtha contaminated with crude, heavy residue, C4's/residue admixture, naphtha/residue admixture, hydrocarbon gases/residue admixture, hydrogen/residue admixture, gas oil/residue admixture, or any mixture thereof.
  • Non-limiting examples of crudes can be or can include, but are not limited to: Tapis, Murban, Arab Light, Arab Medium, and/or Arab Heavy as examples.
  • the plastic can be or can include polyethylene terephthalate (PETE or PET), polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polystyrene (PS), polycarbonate (PC), polylactic acid (PLA), acrylic (PMMA), acetal (polyoxymethylene, POM), acrylonitrile-butadiene- styrene (ABS), fiberglass, nylon (polyamides, PA), polyester (PES) rayon, polyoxybenzylmethylenglycolanhydride (bakelite), polyurethane (PU), polyepoxide (epoxy), or any mixture thereof.
  • PETE or PET polyethylene terephthalate
  • PE polyethylene
  • PP polypropylene
  • PVVC polyvinyl chloride
  • PVDC polyvinylidene chloride
  • PS polystyrene
  • PC polycarbonate
  • PLA polylactic acid
  • PMMA acrylic
  • ABS acrylonit
  • the rubber can be or can include natural rubber, synthetic rubber, or a mixture thereof.
  • the biomass can be or can include, but is not limited to, wood, agricultural residues such as straw, stover, cane trash, and green agricultural wastes, agro-industrial wastes such as sugarcane bagasse and rice husk, animal wastes such as cow manure and poultry litter, industrial waste such as black liquor from paper manufacturing, sewage, municipal solid waste, food processing waste, or any mixture thereof.
  • the biogas can be produced via anaerobic digestion, e.g., the biogas produced during the anaerobic digestion of sewage.
  • the biobased oil can be or can include oils that can degrade biologically over time.
  • the biobased oil can be degraded via processes of bacterial decomposition and/or by the enzymatic biodegradation of other living organisms such as yeast, protozoans, and/or fungi.
  • Biobased oils can be derived from vegetable oils, e.g., rapeseed oil, castor oil, palm oil, soybean oil, sunflower oil, corn oil, hemp oil, or chemically synthesized esters.
  • the hydrocarbon-containing feed includes material that is solid at room temperature (solid material), e.g., plastic, biomass, coal, and/or rubber, the solid material can be reduced to any desired particle size via well-known processes.
  • the solid material can be ground, crushed, pulverized, other otherwise reduced into particles that have any desired average particle size.
  • the solid matter can be reduced to an average particle size that can be submicron or from about 1 pm, about 10 pm or about 50 pm to about 100 pm, about 150 pm, or about 200 pm.
  • the average particle size of the hydrocarbon feedstock, if solid matter can range from about 75 pm to about 475 pm, from about 125 pm to about 425 pm, or about 175 pm to about 375 pm.
  • one or more vapor- liquid separators can be used to separate a hydrocarbon-containing feed, e.g., a raw crude oil or a desalted crude oil, to obtain an overhead vapor effluent and a bottoms liquid effluent.
  • a hydrocarbon-containing feed e.g., a raw crude oil or a desalted crude oil
  • the bottoms liquid effluent can have a cutoff point from 300°C to 700°C, e.g., 310°C to 550°C, as measured according to ASTM D1160-18.
  • the hydrocarbon-containing feed can be or can be obtained from the bottoms liquid effluent.
  • At least a portion of the overhead vapor effluent can optionally be fed into another processing unit, e.g., a radiant section of a steam cracker furnace, a fluid catalytic cracker, other systems capable of upgrading the overhead vapor effluent, or any combination thereof.
  • Suitable vaporization drums or flashing drums can include those disclosed in U.S. Patent No. 7,674,366; 7,718,049; 7,993,435; 8,105,479; and 9,777,227.
  • the overhead vapor can be steam cracked according to the processes and systems disclosed in U.S. Patent Nos. 6,419,885; 7,993,435; 9,637,694; and 9,777,227; U.S. Patent Application Publication No. 2018/0170832; and International Patent Application Publication No. WO 2018/111574.
  • the processes for converting the hydrocarbon-containing feed, e.g., a crude oil or a fraction thereof, by pyrolysis disclosed herein can produce a pyrolysis effluent that can include, but is not limited to, olefins, e.g., ethylene, propylene, and/or one or more butenes, aromatics, e.g., benzene, toluene, and/or xylene, molecular hydrogen (Fp), or any mixture thereof.
  • the hydrocarbon-containing feed can be introduced, supplied, or otherwise fed into a pyrolysis reaction zone.
  • the hydrocarbon-containing feed can be heated, e.g.
  • a plurality of fluidized particles can also be introduced, supplied, or otherwise fed into the pyrolysis reaction zone.
  • the plurality of fluidized particles can have a first temperature when fed into the pyrolysis reaction zone.
  • the first temperature can be sufficiently high to enable pyrolysis of at least a portion of the hydrocarbon-containing feed or fraction thereof on contacting the particles within the pyrolysis reaction zone.
  • the plurality of fluidized particles can include an oxide of a transition metal element capable of oxidizing molecular hydrogen (3 ⁇ 4) at the first temperature.
  • the hydrocarbon-containing feed can contact the plurality of fluidized particles in the pyrolysis reaction zone to effect pyrolysis of at least a portion of the hydrocarbon-containing feed to produce the pyrolysis effluent that can include olefins, hydrogen, and the particles.
  • the pyrolysis effluent can be at a second temperature that can be lower than the first temperature.
  • At least a portion of the transition metal element disposed on and/or in the particles in the pyrolysis effluent can be at a reduced state as compared to the transition metal element in the plurality of fluidized particles fed into the pyrolysis reaction zone.
  • the first temperature can be 750°C, 800°C, 850°C, 900°C, or 950°C to 1,050°C, 1,100°C, 1,200°C, 1,300°C, 1,400°C, or 1,500°C.
  • the first temperature can be at least 800°C, at least 820°C, at least 840°C, at least 850°C, at least 875°C, at least 900°C, at least 950°C, or at least 975 °C to 1,000°C, 1,050°C, 1,100°C, 1,200°C, 1,300°C, or 1,400°C.
  • the hydrocarbon-containing feed can be contacted with an amount of the plurality of fluidized particles within the pyrolysis reaction zone sufficient to effect a desired level or degree of pyrolysis of the hydrocarbon-containing feed.
  • a weight ratio of the plurality of fluidized particles to the hydrocarbon-containing feed when contacted within the pyrolysis reaction zone can be 5:1, 10:1, 12:1, 15:1, or 20:1 to 25:1, 30:1, 35:1, 40:1, 45:1, 50:1, 55:1, or 60:1.
  • the pyrolysis reaction zone can be located in any suitable reactor or other process environment capable of operating under the pyrolysis process conditions.
  • the pyrolysis reaction zone can be located in short contact time fluid bed.
  • the pyrolysis reaction zone can be located in a downflow reactor, an upflow reactor, a counter- current flow reactor, or vortex reactor.
  • the pyrolysis reaction zone can be located in a downflow reactor.
  • the hydrocarbon-containing feed can be contacted with the plurality of fluidized particles in the pyrolysis reaction zone in the presence of steam.
  • the steam if present, can be introduced or otherwise fed into the pyrolysis reaction zone in an amount sufficient to provide a weight ratio of the steam to the hydrocarbon-containing feed of 0.05:1, 0.1:1, 0.2:1, 0.25:1, 0.3:1, or 0.4:1 to 0.5:1, 0.6:1, 0.7:1, 0.8:1, 0.9:1, or 1:1.
  • the weight ratio of the steam to the hydrocarbon-containing feed can be about 0.2:1 to about 0.6:1 or about 0.3:1 to about 0.5:1.
  • the hydrocarbon-containing feed can contact the plurality of fluidized particles within the pyrolysis reaction zone under a vacuum, at atmospheric pressure, or at a pressure greater than atmospheric pressure.
  • the hydrocarbon-containing feed can contact the plurality of fluidized particles within the pyrolysis reaction zone under an absolute pressure of 101 kPa, 150 kPa, 200 kPa, 250 kPa, 300 kPa, or 400 kPa to 450 kPa, 500 kPa, 550 kPa, 600 kPa, 650 kPa, 700 kPa, 750 kPa, 800 kPa, or 840 kPa.
  • the hydrocarbon-containing feed can contact the plurality of fluidized particles within the pyrolysis reaction zone under an absolute pressure of 101 kPa to 800 kPa, 101 kPa to 700 kPa, 101 kPa to 500 kPa, 200 kPa to 800 kPa, 220 kPa to 460 kPa, or 101 kPa to 450 kPa.
  • the hydrocarbon-containing feed can contact the plurality of fluidized particles within the pyrolysis reaction zone under an absolute pressure of less than 800 kPa, less than 700 kPa, less than 600 kPa, less than 500 kPa, less than 450 kPa, less than 400 kPa, less than 350 kPa, less than 300 kPa, less than 250 kPa, less than 200 kPa, or less than 150 kPa.
  • the hydrocarbon-containing feed can contact the plurality of fluidized particles within the pyrolysis reaction zone for a residence time of 1 millisecond (ms), 5 ms, 10 ms, 25 ms, 50 ms, 75 ms, or 100 ms to 300 ms, 500 ms, 750 ms, 1,000 ms, 1,250 ms, 1,500 ms, 1,750 ms, or 2,000 ms.
  • ms millisecond
  • the hydrocarbon-containing feed can contact the plurality of fluidized particles within the pyrolysis reaction zone for a residence time of 10 ms to 500 ms, 10 ms to 100 ms, 20 ms to 200 ms, 30 ms to 225 ms, 50 ms to 250 ms, 125 ms to 500 ms, 200 ms to 600 ms, or 20 ms to 140 ms.
  • the hydrocarbon-containing feed can contact the plurality of fluidized particles within the pyrolysis reaction zone for a residence time of less than 1,000 ms, less than 800 ms, less than 600 ms, less than 400 ms, less than 300 ms, less than 200 ms, less than 150 ms, or less than 100 ms.
  • the particles that include the oxide of the transition metal element capable of oxidizing molecular hydrogen at the first temperature can do so via one or more processes or mechanisms. Regardless of the overall mechanism, the oxidized transition metal element can facilitate the conversion of molecular hydrogen to water and in doing so the oxidation state of the oxide of the transition metal element can be reduced.
  • the transition metal element is vanadium
  • the oxide of vanadium on the fluidized particles fed into the pyrolysis reaction zone can be at an oxidation state of +5 (for example) and at least a portion of the oxide of vanadium on the fluidized particles in the pyrolysis effluent can be at an oxidation state of +4, +3, or +2.
  • one or more of the oxides of one or more transition metal elements may be capable of being reduced from an oxidized state all the way to the metallic state.
  • the oxide of the transition metal element can favor the conversion, e.g. , oxidation and/or combustion, of hydrogen over the oxidation and/or combustion of hydrocarbons, e.g., olefins, in the pyrolysis reaction zone.
  • the oxide of the transition metal element can favor the conversion of hydrogen over the conversion of hydrocarbons at a rate of 2:1, 3:1, 4:1, 5:1, 6:1, or7:l to 8:1, 9:1, 10:1, or 11:1.
  • the presence of the oxide of the transition metal in the fluidized particles can reduce an amount of molecular hydrogen present in the pyrolysis effluent as compared to a comparative pyrolysis effluent produced under the same process conditions and with the same fluidized particles except the oxide of the transition metal is absent.
  • the amount of molecular hydrogen (3 ⁇ 4) in the pyrolysis effluent in the pyrolysis effluent as compared to a comparative pyrolysis effluent can be reduced by 0.001%, 0.01%, or 0.05% to 0.07%, 0.08%, 0.09%, 0.1%, 0.15%, or 0.2% as compared to the comparative pyrolysis effluent.
  • the amount of molecular hydrogen (3 ⁇ 4) in the pyrolysis effluent in the pyrolysis effluent as compared to a comparative pyrolysis effluent can reduced by at least 0.001%, at least 0.01%, at least 0.05%, or at least 0.07% as compared to the comparative pyrolysis effluent.
  • the amount of molecular hydrogen present in the pyrolysis effluent can be less than 3 wt%, less than 2.5 wt%, less than 2 wt%, less than 1.5 wt%, less than 1.4, less than 1.3 wt%, less than 1.2 wt%, less than 1.1 wt%, less than 1 wt%, less than 0.9 wt%, less than 0.8 wt%, less than 0.7 wt%, less than 0.6 wt%, less than 0.5 wt%, or less than 0.4 wt%.
  • the amount of molecular hydrogen present in the pyrolysis effluent can be 0.01 wt% to 2.5 wt%, 0.5 wt% to 2 wt%, or 1 wt% to 1.7 wt%.
  • coke can be formed on the surface of the particles.
  • the hydrocarbon-containing feed includes non-volatile components at least a portion of the non-volatile components can deposit, condense, adhere, or otherwise become disposed on the surface of the particles and/or at least partially within the particles, e.g., within pores of the particles, in the form of coke.
  • the pyrolysis effluent can include the plurality of particles in which at least a portion of the transition metal element can be at a reduced state and at least a portion of the particles can include coke formed or otherwise disposed on the surface thereof and/or at least partially therein.
  • the particles in the pyrolysis effluent can include 1 wt%, 3 wt%, 5 wt%, 7 wt%, 10 wt%, or 15 wt% to 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, or 50 wt% of coke, based on a total weight of the particles.
  • the plurality of fluidized particles can be or include a core and at least one transition metal element and/or at least one oxidized transition metal element disposed on and/or in the core.
  • the core can be inert, /. ⁇ ? ., inert during pyrolysis of the hydrocarbon- containing feed.
  • the core can be or can include, but is not limited to, silica, alumina, titania, zirconia, magnesia, pumice, ash, clay, diatomaceous earth, bauxite, spent fluidized catalytic cracker catalyst, or any mixture or combination thereof.
  • Preferred support materials can be or can include A1 2 0 3 , Zr0 2 , Si0 2 , and combinations thereof, more preferably, Si0 2 , A1 2 0 3 , or Si0 2 /Al 2 0 3 .
  • the transition metal element and/or the oxide thereof can be disposed on and/or within, e.g., within pores, of the core. In some examples, the transition metal element and/or the oxide thereof can form a surface layer on the core. The surface layer on the core can be continues or discontinuous.
  • the core and/or the particles that include the at least one transition metal element and/or at least one oxidized transition metal element disposed on and/or in the core can have an average size in a range from 10 micrometers (pm), 15 pm, 25 pm, 50 pm, or 75 pm to 150 pm, 200 pm, 300 pm, 400 pm.
  • the core and/or the particles that include the at least one transition metal element and/or at least one oxidized transition metal element disposed on and/or in the core can have a surface area in a range from 10 m 2 /g, 50 m 2 /g, or 100 m 2 /g to 200 m 2 /g, 500 m 2 /g, or 700 m 2 /g.
  • the fluidized particles can be, can include, or can otherwise be derived from spent fluid catalytic converter (“FCC”) catalyst.
  • FCC fluid catalytic converter
  • a significant and highly advantageous use for spent FCC catalyst has been discovered because the processes disclosed herein can significantly extend the useful life of FCC catalyst in upgrading hydrocarbons long after the FCC catalyst is considered to be spent and no longer useful in the fluid catalytic cracking process.
  • the plurality of fluidized particles can include any oxide of a transition metal element capable of converting at least a portion of any hydrogen to water, e.g., via oxidation, combustion, or other mechanism, within the pyrolysis reaction zone.
  • the transition metal element can be or can include, but is not limited to, titanium, vanadium, chromium, manganese, iron, cobalt, niobium, nickel, molybdenum, tantalum, tungsten, alloys thereof, and mixtures thereof.
  • the transition metal element can be or can include vanadium, nickel, an alloy thereof, or a mixture thereof.
  • the amount of transition metal element disposed on and/or at least partially within the plurality of fluidized particles can be in a range from 500 wppm, 750 wppm, 1,000 wppm, 2,500 wppm, 5,000 wppm, or 1 wt% to 2 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, 30 wt%, 40 wt%, or 50 wt%, based on a total weight of the particles.
  • the amount of transition metal element disposed on and/or at least partially within the plurality of fluidized particles can be at least 1 wt%, at least 2.5 wt%, at least 3 wt%, at least 3.5 wt%, at least 4 wt%, at least 4.5 wt%, at least 5 wt%, or at least 10 wt% up to 15 wt%, 20 wt%, 30 wt%, 40 wt%, or 50 wt%.
  • the process conditions within the pyrolysis reaction zone can be sufficient to cause at least a portion of any transition metal in the hydrocarbon-containing feed to deposit, condense, adhere, or otherwise become disposed on the surface of the particles and/or at least partially within the particles.
  • additional transition metal element can become disposed on the plurality of particles.
  • the additional transition metal element can be the same or different than the transition metal element already disposed on the plurality of particles.
  • the particles fed into the pyrolysis reaction zone can include an oxide of a first transition metal disposed on and/or in the particles and the particles discharged from the pyrolysis reaction zone as a component of the pyrolysis effluent can include the oxide of the first transition metal element and a second transition metal element and/or an oxide of the second transition metal element disposed on and/or in the particles. At least a portion of the oxide of the first transition metal element in the pyrolysis effluent can be in a reduced state relative to the oxide of a first transition metal disposed on and/or in the particles when fed into the pyrolysis reaction zone.
  • the first transition metal element can be or can include, but is not limited to, titanium, vanadium, chromium, manganese, iron, cobalt, niobium, nickel, molybdenum, tantalum, tungsten, alloys thereof, and mixtures thereof and the second transition metal element can be or can include, but is not limited to, titanium, vanadium, chromium, manganese, iron, cobalt, niobium, nickel, molybdenum, tantalum, tungsten, alloys thereof, and mixtures thereof.
  • the first transition metal element and the second transition metal element can be the same. In other examples, the first transition metal element and the second transition metal element can be different.
  • the fluidized particles can be or can include inert cores without any transition metal element or oxide thereof disposed on and/or in the inert cores.
  • the fluidized particles can be or can include the inert cores with an undesirably low amount of transition metal element or oxide thereof disposed on and/or in the inert cores.
  • These inert cores free of or containing less than the desired amount of transition metal element or oxide thereof disposed on and/or in the inert cores can be referred to as “starter particles”.
  • starter particles can be derived from a fluid catalytic converter catalyst.
  • a plurality of the starter particles and a source material for the transition metal element can be fed into the pyrolysis reaction zone.
  • the starter particles can be contacted with the source material for the transition metal element in the pyrolysis reaction zone to obtain a contacting mixture effluent that can include the starter particles having a layer of the source material for the transition metal element deposited thereon.
  • At least a portion of the starter particles having the layer of the source material for the transition metal element can be heated and oxidized in the combustion zone to form the particles that can include the oxide of the transition metal element.
  • the source material for the transition metal element can be or can include, but is not limited to, the hydrocarbon-containing feed, a feed containing the desired transition metal(s) and a carrier fluid, e.g., fine particles of the transition metal element and/or fine particles of an oxide of the transition metal element and a hydrocarbon as the carrier fluid.
  • a carrier fluid e.g., fine particles of the transition metal element and/or fine particles of an oxide of the transition metal element and a hydrocarbon as the carrier fluid.
  • the particles can be fabricated from a transition metal element- containing material, e.g., a physical mixture of a transition metal oxide and a binder such as clay, which can result in the distribution of the transition metal element throughout the particles.
  • the particles can be fabricated from transition metal element-free support particles, followed by impregnation of the support particles with a transition metal compound solution, followed by drying and calcination, which can result in the distribution of the transition metal element throughout the particles if the support particles are porous or a distribution of the transition metal element in a surface layer if the support particles are non- porous.
  • transition metal element-free support particles can be charged into the pyrolysis zone and contacted with a transition metal element-containing in the hydrocarbon-containing feed or a feed containing the desired transition metal element(s) and a carrier fluid to form transition metal element-containing particles in situ, which can result in the distribution of the transition metal element throughout the particles if the support particles are porous or a distribution or the transition metal element in a surface layer if the support particles are non-porous.
  • a first hydrocarbon stream rich in hydrocarbons and a first particle stream rich in the particles can be recovered or otherwise obtained from the pyrolysis effluent.
  • the pyrolysis effluent can be fed from the pyrolysis reaction zone into a first separation vessel configured or adapted to receive the pyrolysis effluent and separate the first hydrocarbon stream rich in hydrocarbons and the first particle stream rich in particles from the pyrolysis effluent.
  • the first separation vessel can be configured or adapted to discharge the first hydrocarbon stream and the first particle stream therefrom.
  • the particles in the pyrolysis effluent can optionally be stripped by contacting the particles in the pyrolysis effluent with a first stripping medium within the first separation vessel.
  • the pyrolysis effluent can be fed from the pyrolysis reaction zone into the first separation vessel, which can be configured or adapted to contact the pyrolysis effluent or at least at portion of the particles in the pyrolysis effluent with a first stripping medium, e.g., a steam stream, and separate the pyrolysis effluent to obtain the first hydrocarbon stream rich in hydrocarbons and rich in the optional first stripping medium and the first particle stream rich in particles.
  • a first stripping medium e.g., a steam stream
  • the first separation vessel can also be referred to a stripping vessel.
  • a residence time of the particles in the pyrolysis effluent separated within the first separation vessel from the pyrolysis effluent can be in a range from 30 seconds, 1 minute, 3 minutes, 5 minutes, or 10 minutes to 15 minutes, 17 minutes, 20 minutes, or 25 minutes before being discharged therefrom as the first particle stream rich in particles.
  • the first separation vessel can include an inertial separator configured to separate a majority of the particles from the hydrocarbons to produce the first hydrocarbon stream rich in hydrocarbons and the first particle stream rich in the particles.
  • Inertial separators can be configured or adapted to concentrate or collect the particles by changing a direction of motion of the pyrolysis effluent such that the particle trajectories cross over the hydrocarbon gas streamlines and the particles are either concentrated into a small part of the gas flow or are separated by impingement onto a surface.
  • a suitable inertial separator can include a cyclone.
  • pyrolysis effluent when introduced into a cyclone can undergo a vortex motion so that the hydrocarbon gas acceleration is centripetal and the particles, therefore, move centrifugally towards the outside of the cyclone, /. ⁇ ? ., an inner surface of the cyclone.
  • Illustrative cyclones can include, but are not limited to, those disclosed in U.S. Patent Nos. 7,090,081; 7,309,383; and 9,358,516.
  • the optional first stripping medium e.g., steam
  • the optional first stripping medium can fed into the first separation vessel.
  • the optional first stripping medium can fed into the first separation vessel at a weight ratio of the first stripping medium to the pyrolysis effluent fed into the first separation vessel in a range from 1:1,000, 2:1,000, or 2.5:1,000, or 3:1,000 to 4:1,000, 6:1,000, 8:1,000, or 10:1,000.
  • a residence time within the separation vessel of the hydrocarbons in the pyrolysis effluent separated from the pyrolysis effluent can be less than 1,000 ms, less than 750 ms, less than 500 ms, less than 250 ms, less than 100 ms, less than 75 ms, less than 50 ms, or less than 25 ms.
  • a residence time within the separation vessel of the hydrocarbons in the pyrolysis effluent separated from the pyrolysis effluent can be in a range from 2 ms, 4 ms, 6 ms, or 8 ms to to 10 ms, 12 ms, 14 ms, 16 ms, 18 ms, or 20 ms before being discharged therefrom as the first hydrocarbon stream.
  • the residence time within the separation vessel of the hydrocarbons in the pyrolysis effluent separated within from the pyrolysis effluent can be less than 20 ms, less than 15 ms, less than 10 ms, less than 7 ms, less than 5 ms, or less than 3 ms before being discharged therefrom as the first hydrocarbon stream.
  • the first hydrocarbon stream rich in hydrocarbons, upon being discharged from the first separation vessel, can be free or substantially free of any particles.
  • the first hydrocarbon stream discharged from the first separation vessel can include less than 25 wt%, less than 20 wt%, less than 15 wt%, less than 12 wt%, less than 10 wt%, less than 8 wt%, less than 6 wt%, less than 5 wt%, less than 3 wt%, or less than 1 wt% of the particles present in the pyrolysis effluent.
  • a residence time of the hydrocarbons in the first hydrocarbon stream separated from the pyrolysis effluent spanning from the initial introduction of the hydrocarbon-containing feed and fluidized particles into the pyrolysis zone to the recovery of the first hydrocarbon stream rich in hydrocarbons from the first separation vessel can be 5 ms, 10 ms, 25 ms, 50 ms, 75 ms, or 100 ms to 300 ms, 500 ms, 750 ms, 1,000 ms, 1,250 ms, 1,500 ms, 1,750 ms, or 2,000 ms.
  • residence time of the hydrocarbons in the first hydrocarbon stream separated from the pyrolysis effluent spanning from the initial introduction of the hydrocarbon-containing feed and fluidized particles into the pyrolysis zone to the recovery of the first hydrocarbon stream rich in hydrocarbons from the first separation vessel can be less than 1,500 ms, less than 1,250 ms, less than 1,000 ms, less than 800 ms, less than 600 ms, less than 400 ms, less than 300 ms, less than 200 ms, less than 150 ms, or less than 100 ms.
  • the first hydrocarbon stream rich in hydrocarbons and optionally the first stripping medium can be at a temperature in a range from 800°C, 850°C, or 900°C to 950°C, 1,000°C, 1,100°C, or 1,200°C upon discharge from the first separation vessel.
  • the first hydrocarbon stream can be cooled to a temperature of less than 750°C, less than 700°C, less than 650°C, less than 600°C, less than 550°C, less than 500°C, less than 450°C, or less than 400°C.
  • the first hydrocarbon stream can be cooled to a temperature of in a range from 250°C, 300°C, 350°C, 400°C, 450°C, or 500°C to less than 700°C, less than 675 °C, less than 650°C, less than 625°C, less than 600°C, less than 550°C, or less than 500°C.
  • the first hydrocarbon stream can be cooled from the temperature upon discharge from the first separation vessel to the temperature of the cooled first hydrocarbon stream in a range from 1 ms, 3 ms, 5 ms, or 7 ms to 10 ms, 12 ms, 15 ms, or 20 ms. In other examples, the first hydrocarbon stream can be cooled from the temperature upon discharge from the first separation vessel to the temperature of the cooled first hydrocarbon stream in less than 20 ms, less than 15 ms, less than 10 ms, less than 7 ms, less than 5 ms, less than 4 ms, less than 3 ms, less than 2 ms, or less than 1 ms.
  • a preferred process for cooling the first hydrocarbon stream can include indirectly exchanging heat from the first hydrocarbon stream to a quenching medium, e.g., water (liquid or gaseous), quenching oil, or other fluid to produce a cooled first hydrocarbon stream.
  • a quenching medium e.g., water (liquid or gaseous), quenching oil, or other fluid to produce a cooled first hydrocarbon stream.
  • Suitable heat exchangers can be or can include, but are not limited to, shell-and-tube heat exchanger, a plate and frame heat exchanger, brazed aluminum heat exchangers, a plate and fin heat exchanger, a spiral wound heat exchanger, a coil wound heat exchanger, a U-tube heat exchanger, a bayonet style heat exchanger, any other apparatus, or any combination thereof.
  • a preferred process for cooling the first hydrocarbon stream can include injecting a quenching medium, e.g., a quenching oil, into the first hydrocarbon stream in a quenching section downstream, e.g., a transfer line exchanger (“TLE”), of the first separation vessel to produce the cooled first hydrocarbon stream.
  • a quenching medium e.g., a quenching oil
  • TLE transfer line exchanger
  • the first hydrocarbon stream can be cooled by indirectly exchanging heat and by contacting with a quenching medium.
  • the first hydrocarbon stream can have a temperature in a range from 800°C, 850°C, or 900°C to 950°C, 1,000°C, 1,100°C, or 1,200°C when initially contacted with the quenching medium or when heat is initially transferred from the first hydrocarbon stream to a heat transfer medium in a heat exchanger.
  • any suitable quenching medium(s) having a temperature and/or heat capacity capable of reducing the temperature of the first hydrocarbon stream to a desirable level via direct contact and/or indirect contact can be used.
  • the quenching medium can be or can include, but is not limited to, water, a quench oil, a gas oil, naphtha, a stream rich in paraffins, or the like.
  • the quench medium can be or can include a recycled quench oil, a recycled gas oil, a recycled naphtha, a recycle stream rich in paraffins, or the like separated from the first hydrocarbon stream in a downstream separation process.
  • the quenching medium can be or can include a stream of quenching oil separated from the first hydrocarbon stream in a downstream distillation column.
  • at least a portion of a stream rich in paraffins separated from the first hydrocarbon stream in a downstream separation system, e.g., a recovery sub-system can be injected into the first hydrocarbon stream in the quenching section to combine with the first hydrocarbon stream to form a mixture having a temperature substantially lower than the first hydrocarbon stream upon being discharged from the first separation vessel.
  • the first hydrocarbon stream upon being discharged from the first separation vessel can be at a temperature sufficient to effect pyrolysis of at least a portion of the hydrocarbons in the quench medium.
  • the amount of olefins in the cooled or quenched first hydrocarbon steam can be increased relative to the first hydrocarbon stream upon being discharged from the first separation reactor.
  • the first hydrocarbon stream can be contacted with a quench medium that includes one or more paraffins, e.g., ethane, propane, butane, pentane, hexane, or a mixture thereof.
  • a quench medium that includes one or more paraffins
  • the amount of C4- olefins in the quenched first hydrocarbon stream can be increased relative to the amount of C4- olefins in the first hydrocarbon stream recovered from the first separation vessel because at least a portion of the paraffins can be cracked to produce additional olefins.
  • the time from contacting at least a portion of the hydrocarbon-containing feed with the particles in the pyrolysis reaction zone to indirectly exchanging heat to a quenching medium and/or contacting the first hydrocarbon stream with a quenching medium can be in a range from 10 ms, 25 ms, 50 ms, 75 ms, or 100 ms to 300 ms, 500 ms, 750 ms, 1,000 ms, 1,250 ms, 1,500 ms, 1,750 ms, or 2,000 ms.
  • the time from contacting at least a portion of the hydrocarbon-containing feed with the particles in the pyrolysis reaction zone to indirectly exchanging heat to the quenching medium and/or contacting the first hydrocarbon stream with the quenching medium can be less than 2,000 ms, less than 1,500 ms, less than 1,000 ms, less than 800 ms, less than 600 ms, less than 400 ms, less htan 200 ms, less than 150 ms, less than 100 ms, less than 75 ms, or less than 50 ms.
  • the cooled first hydrocarbon stream can include, but is not limited to, one or more of the following: hydrogen, methane, ethane, ethylene, propane, propylene, butenes, naphtha, gas oil, a heavy oil, and tar.
  • the naphtha, gas oil, heavy oil, and tar each include a mixture of compounds, primarily a mixture of hydrocarbon compounds. It should be understood that typically there is an overlap between naphtha and gas oil, an overlap between gas oil and heavy oil or quench oil, and an overlap between heavy oil and tar in composition and boiling point range.
  • Naphtha also referred to as pygas
  • pygas is a complex mixture of C5 + hydrocarbons, e.g., C5- C10 + hydrocarbons, having an initial atmospheric boiling point of 25°C to 50°C and a final boiling point of 220°C to 265°C, as measured according to ASTM D2887-18.
  • naphtha can have an initial atmospheric boiling point of 33°C to 43 °C and a final atmospheric boiling point of 234°C to 244°C, as measured according to ASTM D2887-18.
  • the final atmospheric boiling point of the gas oil is typically 275°C to 285°C, as measured according to ASTM D2887-18.
  • the final atmospheric boiling point of the heavy oil or quency oil is typically 455°C to 475°C, as measured according to ASTM D2887-18.
  • the tar product can have an initial boiling point of at least 200°C and/or a final atmospheric boiling point of > 600°C, as measured according to ASTM D2887-18.
  • the cooled first hydrocarbon stream can be separated to obtain a second hydrocarbon stream rich in hydrocarbons and a third particle stream rich in the particles.
  • separating the cooled first hydrocarbon stream can include using a cyclone.
  • the cooled first hydrocarbon stream can be fed into a third separation vessel configured or adapted to receive the cooled first hydrocarbon stream and separate the second hydrocarbon stream rich in hydrocarbons and the third particle stream rich in particles therefrom.
  • the third separation vessel can be configured or adapted to discharge the second hydrocarbon stream and the third particle stream therefrom.
  • the particles in the cooled first hydrocarbon stream can optionally be stripped by contacting at least a portion of the particles in the cooled first hydrocarbon stream with a third stripping medium within the third separation vessel.
  • the cooled first hydrocarbon stream can be fed into the third separation vessel, which can be configured or adapted to contact at least a portion of the particles in the cooled first hydrocarbon stream with the third stripping medium, e.g., a steam stream, to obtain the second hydrocarbon stream rich in hydrocarbons and rich in the optional third stripping medium and the third particle stream rich in the particles.
  • the third separation vessel can also be referred to as a stripping vessel or as including a stripping zone or stripping vessel.
  • the third separation vessel can be or can include one or more multi-cyclone (multi-clone) separators.
  • the third separation vessel can include the conventional separators are available from several vendors, such as the Polutrol, Shell and Emtrol, such as the Polutrol TSS and the Emtrol Cytrol TSS.
  • the second hydrocarbon stream rich in hydrocarbons can include less than 1 wt%, less than 0.7 wt%, less than 0.5 wt%, less than 0.3 wt%, or less than 0.1 wt% of any particles.
  • at least a portion of the third particle stream can rich in the particles can be introduced into the first separation vessel, e.g. , a stripping zone within the first separation vessel.
  • at least a portion of the third particle stream rich in particles can be recycled to the combustion zone.
  • at least a portion of the third particle stream can be removed from the process.
  • a first portion of the third particle stream can be introduced into the first separation vessel and/or recycled to the combustion zone and a second portion of the third particle stream can be removed from the process.
  • the second hydrocarbon stream rich in hydrocarbons can be further cooled, e.g., indirect heat exchange with a heat transfer medium, quenching with a quench medium, e.g., a portion of the heavy oil or other stream(s) separated from the second hydrocarbon stream via one or more downstream separation processes, water, or the like.
  • a quench medium e.g., a portion of the heavy oil or other stream(s) separated from the second hydrocarbon stream via one or more downstream separation processes, water, or the like.
  • the second hydrocarbon stream or the further cooled second hydrocarbon stream can be separated to obtain two or more products therefrom.
  • the second hydrocarbon stream can be separated within a fractionation zone to obtain a bottoms heavy stream, a gas oil stream, and an overhead stream rich in naphtha and light hydrocarbons.
  • the overhead stream can be further separated to obtain a naphtha stream, at least one olefin stream rich in one or more olefins, and at least one hydrogen stream rich in hydrogen.
  • the overhead stream can also be separated to obtain the stream rich in paraffins, which, as discussed above, can be used as at least a portion of the quench medium contacted with the first hydrocarbon stream to produce the quenched first hydrocarbon stream.
  • the gas oil stream can be used as the quenching medium that can contact the first hydrocarbon stream rich in hydrocarbons to produce the quenched first hydrocarbon stream.
  • a first portion of the gas oil stream can be used as the quenching medium and a second portion can be removed from the process.
  • the bottoms heavy stream can be cooled in one or more heat exchanges by indirectly exchanging heat to a heat transfer medium, e.g., boiler feed water, to produce a cooled bottoms heavy stream and a pre-heated boiler feed water.
  • the preheated boiler feed water can be used to cool the second hydrocarbon stream rich in hydrocarbons by indirectly exchanging heat.
  • a portion or first portion of the cooled bottoms heavy stream can be contacted with the second hydrocarbon steam rich in hydrocarbons or the cooled second hydrocarbon stream rich in hydrocarbons as a quench medium.
  • a portion or second portion of the cooled bottoms heavy stream can be fed into the combustion zone as the fuel or as at least a portion of the fuel that can optionally be fed thereto.
  • the particles in the first particle stream can be fed into the combustion zone.
  • the first particle stream can be oxidized and heated under conditions sufficient such that at least a portion of the transition metal element in the particles can be oxidized to a higher oxidation state as compared to the transition metal element in and/or at least partially within the particles in the pyrolysis effluent to produce a combustion zone effluent.
  • An oxidant or oxidizing agent and optionally a fuel can be fed into the combustion zone in addition to the first particle stream rich in particles.
  • the oxidizing agent can be or can include molecular oxygen.
  • the oxidizing agent can be or can include air, oxygen enriched air, oxygen depleted air, or any mixture thereof.
  • the fuel can be or can include any combustible source of material capable of combusting in the presence of the oxidizing agent within the pyrolysis reaction zone. Suitable fuels can be or can include, but are not limited to, naphtha, gas oil, fuel oil, quench oil, fuel gas, molecular hydrogen, or any mixture thereof. In some examples, the fuel can be or can include a bottoms heavy oil stream separated from the first hydrocarbon stream.
  • the combustion zone effluent which can include heated and oxidized particles and a flue gas, can be obtained from the combustion zone.
  • the first particle stream rich in particles fed into the combustion zone can be oxidized and heated at a temperature in a range from 800°C, 900°C, or 1,000°C to 1,100°C, 1,200°C, or 1,300°C.
  • an amount of the optional fuel that can be introduced into the combustion zone can be sufficient to provide additional heat within the combustion zone to produce the combustion zone effluent that includes the heated and oxidized particles at the desired temperature.
  • the first particle stream rich in particles when the first particle stream rich in particles includes coke disposed on and/or at least partially in the particles, at least a portion of the coke can be combusted within the combustion zone.
  • the heated and oxidized particles in the combustion zone effluent obtained from the combustion zone can include less coke as compared to the particles in the first particle stream rich in particles or can be free of any coke.
  • the particles in the combustion zone effluent can include less than 5 wt%, less than 4 wt%, less than 3 wt%, less than 2 wt%, less than 1 wt%, less than 0.5 wt%, or less than 0.1 wt% of coke.
  • the transition metal element when at a high oxidative state may be less selective toward oxidation of molecular hydrogen as compared to the transition metal element when at a lower oxidative state.
  • an amount of oxidant or oxidizing agent fed into the combustion zone can be controlled or otherwise adjusted to produce the combustion zone effluent that includes the transition metal element at a desired or predetermined oxidized state.
  • the combustion zone can be operated under complete combustion conditions that can produce a combustion zone effluent that includes a flue gas that can contain at least a portion of the oxidizing agent fed into the combustion zone, e.g., 0.5 mol% to 2.5 mol% or 1 mol% to 2 mol% of the oxidizing agent, and a low concentration of carbon monoxide, e.g., less than 1 mol% of carbon dioxide.
  • the combustion zone can be operated under partial combustion conditions that can produce a combustion zone effluent that includes a flue gas that can contain at least 1 mol% of carbon monoxide and less than 0.5 mol%, e.g., 0 mol%, of the oxidizing agent.
  • the flue gas produced during partial combustion can be free or substantially free of any of the oxidizing agent introduced into the combustion zone. Accordingly, the combustion zone can be operated under conditions sufficient to cause at least a portion of the transition metal element in the particles to be oxidized to a higher oxidation state as compared to the transition metal element in the particles in the pyrolysis effluent, but not necessarily oxidized to the highest oxidation state possible for a given transition metal element.
  • At least a portion of the oxidized and heated particles in the combustion zone effluent can be supplied to the pyrolysis reaction zone as at least a portion of the plurality of fluidized particles fed to the pyrolysis reaction zone.
  • the combustion zone effluent can under go one or more optional treatments before feeding at least a portion of the oxidized and heated particles to the pyrolysis reaction zone.
  • the combustion zone effluent can optionally be separated into a second particle stream that can be rich in the heated and oxidized particles and a first flue gas stream that can be rich in flue gas.
  • the combustion zone effluent can be discharged from the combustion zone into a second separation vessel configured or adapted to receive the combustion zone effluent and separate the second particle stream and the flue gas therefrom.
  • the second separation vessel can be configured or adapted to discharge the second particle stream and the first flue gas therefrom.
  • the second particle stream can be recycled or otherwise fed into the pyrolysis reaction zone as at least a portion of the particles fed into the pyrolysis reaction zone.
  • the combustion zone effluent can optionally be stripped by contacting the combustion zone effluent within the second separation vessel with a second stripping medium.
  • the combustion effluent can be fed from the combustion zone into the second separation vessel, which can be configured or adapted to contact the combustion zone effluent with a second stripping medium, e.g., a steam stream, and separate the combustion zone effluent to obtain the second particle stream rich in particles and the first flue gas stream rich in the optional second stripping medium stream.
  • a second stripping medium e.g., a steam stream
  • the first flue gas stream can be at a temperature in a range of 800°C, 900°C, or 1,000°C, to 1,100°C, 1,200°C, or 1,300°C.
  • the first flue gas stream can be quenched by contacting the first flue gas stream with a quenching medium to produce a quenched first flue gas stream.
  • the quenching medium contacted with the first flue gas stream can be or can include, but is not limited to, air, water (liquid or gaseous), or a mixture thereof.
  • the first flue gas stream or the quenched first flue gas stream can be separated to obtain a second flue gas stream rich in flue gas and a fourth particle stream rich in particles.
  • separating the first flue gas stream or the quenched first flue gas stream can include using a cyclone.
  • the first flue gas stream or the quenched first flue gas stream can be fed into a fourth separation vessel configured or adapted to receive the first flue gas stream or the quenched first flue gas stream and separate the second flue gas stream and the fourth particle stream therefrom.
  • the fourth separation vessel can be configured or adapted to discharge the second flue gas stream and the fourth particle stream.
  • At least a portion of the particle sin the first flue gas stream or the quenched first flue gas stream can optionally be stripped by contacting at least a portion of the particles with a fourth stripping medium within the fourth separation vessel.
  • the first flue gas stream or the quenched first flue gas stream can be fed into the fourth separation vessel, which can be configured or adapted to contact at least a portion of the particles with the fourth stripping medium, e.g., a steam stream, to obtain the second flue gas stream rich in flue gas and rich in the optional fourth stripping medium and the fourth particle stream rich in particles.
  • the fourth separation vessel can also be referred to a stripping vessel.
  • the first flue gas stream can be at a temperature sufficiently low, e.g., 875°C or less, to enable the third separation vessel to be constructed of low-temperature metallurgy.
  • the fourth separation vessel can be or can include one or more multi-cyclone (multi-clone) separators.
  • the fourth separation vessel can include the conventional separators are available from several vendors, such as the Polutrol, Shell and Emtrol, such as the Polutrol TSS and the Emtrol Cytrol TSS.
  • the second flue gas stream can be used to indirectly heat one or more process streams.
  • the second flue gas stream can be used to indirectly heat the oxidant or oxidizing agent prior to feeding the oxidizing agent into the combustion zone.
  • the second flue gas stream can also be used to indirectly heat the hydrocarbon-containing feed prior to feeding the hydrocarbon-containing feed into the pyrolysis reaction zone.
  • the second flue gas stream can also be used to indirectly heat boiler feed water to produce steam.
  • the steam can be used as stripping steam, a motive fluid, e.g., to fluidize the particles fed to the pyrolysis reaction zone and/or to fluidize the first particle stream rich in particles, as the optional steam that can be fed into the pyrolysis reaction zone, or any other use that could utilize the steam.
  • the second flue gas stream can be used to indirectly heat any two or more process streams in a serial flow arrangement.
  • the second flue gas stream can be used to indirectly heat the oxidizing agent and produce a first cooled second flue gas
  • the first cooled second flue gas can be used to indirectly heat the hydrocarbon-containing feed and produce a second cooled second flue gas
  • the second cooled second flue gas can be used to indirectly heat the boiler feed water to produce steam and a third cooled second flue gas.
  • a first portion of the second flu gas can be used to heat the oxidizing agent, a second portion of the second flue gas can be used to heat the hydrocarbon-containing feed, and a third portion of the second flue gas can be used to heat the boiler feed water.
  • the second flue gas or the cooled second flue gas can be further treated if needed to remove any sulfur oxide or other contaminants prior to venting the atmosphere or otherwise disposing of.
  • At least a portion of the fourth particle stream rich in particles can be recycled to the combustion zone. In some examples, at least a portion of the fourth particle stream can be removed from the process. In some examples, a first portion of the fourth particle stream can be recycled to the combustion zone and a second portion of the fourth particle stream can be removed from the process.
  • the predetermined amount of the transition metal element and/or the oxide thereof can be in a range from 10 wt%, 12 wt%, or 14 wt% to 16 wt%, 18 wt%, 20 wt%, 22 wt%, or 25 wt%, based on the weight of the particles.
  • the particles can be removed from the process at a rate of about 0.1 wt%, about 0.3 wt%, about 0.5 wt%, about 0.7 wt%, or about 1 wt% to about 1.3 wt%, about 1.5 wt%, about 1.7 wt%, about 2 wt%, about 3 wt%, about 5 wt%, about 10 wt% or more per 24 hours, based on the total weight of particles being circulated through the process.
  • the particles can be removed from the process at a continuous rate or in batches and replace particles can be introduced into the process at a continuous rate or in batches.
  • a portion of the particles can be removed or obtained from the first particle stream rich in particles, the second particle stream rich in particles, the third particle stream rich in particles, or the fourth particle stream rich in particles.
  • replacement particles can be added into the process.
  • the replacement particles can be fed into the combustion zone and/or mixed, blended, or otherwise combined with the hydrocarbon-containing feed and/or any other stream that includes particles such as the first particle stream rich in particles the second particle stream rich in particles, the third particle stream rich in particles, and/or the fourth particle stream rich in particles.
  • the Figure depicts an illustrative system 100 for processing a hydrocarbon-containing feed in line 102, according to one or more embodiments.
  • the system 100 can include, but is not limited to, one or more pyrolysis reactors, e.g., a downflow reactor, 115, one or more first separation vessels 120, one or more combustion vessels 125, one or more second separation vessels 130, and one or more channels 132 configured or adapted to feed a particle stream from second separation vessel 130 to the pyrolysis reactor 115.
  • pyrolysis reactors e.g., a downflow reactor, 115, one or more first separation vessels 120, one or more combustion vessels 125, one or more second separation vessels 130, and one or more channels 132 configured or adapted to feed a particle stream from second separation vessel 130 to the pyrolysis reactor 115.
  • the first separation vessel 120 can include one or more inertial separators 119 that can be configured to separate a majority of the particles from the gaseous hydrocarbons to provide a first hydrocarbon stream rich in hydrocarbons via line 121 and the particles can fall or otherwise flow toward an end or lower portion of the first separation vessel 120.
  • a suitable inertial separator can include a cyclone. The pyrolysis effluent, when introduced into a cyclone can undergo a vortex motion so that the hydrocarbon gas acceleration is centripetal and the particles, therefore, move centrifugally towards the outside of the cyclone, /. ⁇ ? ., an inner surface of the cyclone.
  • Illustrative cyclones can include, but are not limited to, those disclosed in U.S. Patent Nos. 7,090,081; 7,309,383; and 9,358,516.
  • the system 100 can also include one or more first quenching stages or quenching sections 135, one or more third separation vessels 140, and one or more channels two are shown 143, 144 configured or adapted to feed at least a portion of a particle stream from the third separation vessel to the first separation vessel 120 (shown) and/or the combustion vessel 125 (not shown).
  • the system 100 can also include one or more heat exchangers 150 and one or more distillation columns 160.
  • the system 100 can also include one or more channels 162 and/or 173 configured or adapted to feed a side- draw product and/or an overhead product to the quenching zone 135.
  • the system 100 can also include one or more channels (two are shown) 161,166 configured or adapted to feed at least a portion of a bottoms product from the distillation column 160 to the combustor 125.
  • the system 100 can also include one or more recovery sub systems 170.
  • the system 100 can also include one or more fourth separation vessels 185 and one or more channels 187 configured or adapted to feed at least a portion of a particle stream from the fourth separation vessel 185 to the combustion vessel 125.
  • the system 100 can also include one or more heat exchangers 106 and one or more channels 108 configured or adapted to transfer a flue gas stream from the fourth separation vessel 185 to the heat exchanger 106.
  • an oxidant or an oxidizing agent e.g., air
  • the hydrocarbon-containing feed via line 102, and water, e.g., boiler feed water, via line 103 can be fed into one or more first heat exchange stages, e.g. , a first heat exchanger, 105, one or more second heat exchange stages, e.g., a second heat exchanger, 106, and one or more third heat exchange stages, e.g., a third heat exchanger, 107, respectively.
  • a heat source or heated medium, e.g., a combustion or flue gas, via line 108 can be serially fed into the first heat exchange stage 105, the second heat exchange stage 106, and the third heat exchange stage 107, respectively, thereby transferring heat to the oxidant, the hydrocarbon-containing feed, and the boiler feed water, respectively.
  • a heated oxidizing agent via line 110 and a heated hydrocarbon-containing feed via line 111 can be obtained from the first and second heat exchange stages 105, and 106, respectively.
  • Steam via line 112 and a cooled medium, e.g., water, via line 113 can be obtained from the third heat exchange stage 107.
  • At least a portion of the hydrocarbon-containing feed via line 111 and a fluidized stream of particles via line 132 can be fed into the pyrolysis reactor 115.
  • the fluidized stream of particles upon introduction into the pyrolysis reactor 115, can have a first temperature.
  • the hydrocarbon-containing feed can contact the particles within the pyrolysis reactor 115 to effect pyrolysis of at least a portion of the hydrocarbon-containing feed.
  • the first temperature can be sufficiently high to enable the pyrolysis of at least a portion of the hydrocarbon-containing feed.
  • the particles can include an oxide of a transition metal element that can be capable of oxidizing molecular hydrogen (3 ⁇ 4) at the first temperature.
  • At least a portion of the steam via line 112 can optionally be fed into the pyrolysis reactor 115.
  • pyrolysis of the hydrocarbon-containing feed coke can deposit, condense, adhere, or otherwise become disposed on the surface of the particles and/or at least partially within the particles.
  • the hydrocarbon-containing feed in line 111 includes one or more transition metal elements, which can be the same or different than the transition metal element already on the particles when fed into the pyrolysis reactor 115, at least a portion of the transition metal element in the hydrocarbon-containing feed can also deposit, condense, adhere, or otherwise become disposed on the surface of the particles and/or at least partially within the particles.
  • a pyrolysis effluent via outlet 116 can be discharged from the pyrolysis reactor 115 into the first separation vessel 120 configured or adapted to receive and separate the pyrolysis effluent to obtain a first hydrocarbon stream rich in hydrocarbons and a first particle stream rich in the particles.
  • the first hydrocarbon stream rich in hydrocarbons via line 121 and the first particle stream rich in the particles via line 122 can be discharged from the first separation vessel 120.
  • a stripping steam stream or first stripping steam stream via line 118 can optionally be fed into the first separation vessel 120. If the stripping steam stream via line 118 is fed into the first separation vessel 120, the stripping steam stream can improve or otherwise aid in separating the first hydrocarbon stream and the first particle stream from the pyrolysis effluent. If the optional stripping steam stream via line 118 is fed into the first separation vessel 120 the first hydrocarbon stream rich in hydrocarbons discharged via line 121 can also include at least a portion of the steam.
  • the first separation vessel 120 can be or can include one or more cyclones configured or adapted to separate the first hydrocarbon stream and the first particle stream from the pyrolysis effluent.
  • the first particle stream via line 122, the heated oxidizing agent via line 110, and optionally a fuel stream via line 166 can be fed into the combustion vessel 125.
  • steam or other motive fluid via line 123 can be mixed, blended, or otherwise combined with the first particle stream in line 122.
  • the fluid fed via line 123 can fluidize the particles within line 122 to urge or otherwise move the particles into the combustion vessel 125.
  • the combustion vessel 125 can be configured or adapted to combust coke deposited onto the particles during pyrolysis of the hydrocarbon-containing feed.
  • Combustion of the coke disposed on the particles and the option fuel stream within the combustion vessel 125 can produce a combustion zone effluent that can include heated particles, a flue gas, and oxidized particles in which the transition metal element has a higher oxidation state as compared to the transition metal element in the particles in the pyrolysis effluent and the first particle stream rich in the particles in line 122.
  • the combustion vessel 125 can be configured or adapted to discharge the combustion effluent via line 126.
  • the combustion effluent via line 126 can be fed into the second separation vessel 130 that can be configured or adapted to receive and separate the combustion zone effluent to obtain a second particle stream rich in the particles and a first flue gas stream rich in the flue gas.
  • the first flue gas stream via line 131 and the second particle stream via line 132 can be discharged from the second separation vessel 130. As shown in the Figure, the second particle stream via 132 is recycled or otherwise fed into the pyrolysis reactor 115 as the fluidized stream of particles.
  • a stripping steam stream or second stripping steam stream via line 127 can optionally be fed into the second separation vessel 130. If the steam stream via line 127 is fed into the second separation vessel 130, the steam stream can improve or otherwise aid in separating the flue gas stream and the particles from the combustion effluent.
  • the second separation vessel 130 can be or can include one or more cyclones configured or adapted to separate the flue gas and the particles from the combustion effluent.
  • the first hydrocarbon stream via line 121 and a quench medium via line 162 can be fed into one or more quenching sections, e.g., a transfer line exchanger, 135 configured or adapted to produce a quenched mixture stream that includes the quench medium and the first hydrocarbon stream.
  • the quenched mixture stream can be discharged via line 136 from the quenching section 135.
  • the quench medium in line 162 can be or can include a side-draw gas oil stream obtained from the distillation column 160.
  • a stream rich in paraffins via line 173 obtained from the recovery sub-system 170.
  • the first hydrocarbon steam can be at a temperature sufficiently high to enable pyrolysis of at least a portion of the stream rich in paraffins upon contacting with the first hydrocarbon stream.
  • the quenched mixture stream via line 136 can be fed into the third separation vessel
  • the third separation vessel 140 configured or adapted to receive and separate the quenched mixture stream to obtain a second hydrocarbon stream rich in hydrocarbons and a third particle stream rich in the particles.
  • the third separation vessel 140 can be or can include one or more cyclones
  • a stripping steam stream or third stripping steam stream can be fed into the third separation vessel 140. If the stripping steam stream is fed into the third separation vessel 140, the stripping steam stream can improve or otherwise aid in separating the second hydrocarbon stream and the third particle stream from the quenched mixture stream.
  • the second hydrocarbon stream via line 142 and the third particle stream via line 143 can be discharged from the third separation vessel 140.
  • at least a portion of the third particle stream in line 143 can be fed via line 144 into the first separation vessel 120. Feeding the third particle stream via line 144 into the first separation vessel can at least partially cool the pyrolysis effluent fed via the outlet 116 of the pyrolysis reactor 115.
  • at least a portion of the third particle stream in line 143 can be fed via line 144 into the combustion vessel 125 (not shown).
  • at least a portion of the third particle stream in line 143 can be removed via line 145 from the system 100.
  • the removal of at least a portion of the third particle stream via line 145 can be used to control or adjust an amount of particles in the system that during operation can become undesirably rich in the transition metal element disposed thereon.
  • starter particles via line 124 can be fed into the combustion vessel 125, for example.
  • the second hydrocarbon stream via line 142 can be fed into one or more optional heat exchange stages, e.g., a fourth heat exchanger, 150 configured or adapted to receive and cool the second hydrocarbon stream and discharge a cooled second hydrocarbon stream via line 151 therefrom.
  • a pre-heated cooling medium e.g. , a pre-heated boiler feed water
  • line 167 can be fed into the fourth heat exchange stage 150 and steam via line 152 can be obtained therefrom.
  • the second hydrocarbon stream via line 142 or the optionally cooled hydrocarbon stream via line 151 can be fed into the distillation column 160 or optionally into one or more second quenching stages or quenching sections, e.g., a transfer line exchanger, 155.
  • a portion of a cooled bottoms heavy oil stream via line 168 can be mixed, blended, or otherwise combined with the second hydrocarbon stream in line 142 or the optionally cooled second hydrocarbon stream in line 151 to produce a quenched second hydrocarbon stream via line 156.
  • the second hydrocarbon stream via line 142, the cooled second hydrocarbon stream via line 151, or the quenched second hydrocarbon stream via line 156 can be fed into the distillation column 160.
  • the distillation column 160 can separate various hydrocarbon products from the second hydrocarbon stream in line 142, the cooled second hydrocarbon stream in line 151, or the quenched second hydrocarbon stream in line 156.
  • the hydrocarbon products that can be obtained from the distillation column 160 can include, but are not limited to, a bottoms heavy oil stream via line 161, a side-draw gas oil stream via line 162, an overhead stream rich in naphtha and light hydrocarbons via line 163, or a combination thereof.
  • the bottoms heavy oil stream via line 161 and a cooling medium, e.g., boiler feed water, via line 164 can be fed into one or more optional heat exchange stages, e.g. , a fifth heat exchanger, 165 and a cooled bottoms heavy oil stream via line 166 and the pre heated cooling medium via line 167 can be discharged therefrom.
  • a portion of the cooled bottoms heavy oil stream in line 166 can be fed via line 168 into the optional quench stage 155 as the quench medium.
  • at least a portion of the cooled bottoms heavy oil stream via line 169 can be removed from the system 100.
  • the cooled bottoms heavy oil stream via line 166 can be fed into the combustion vessel 125 as the optional fuel stream.
  • the overhead stream via line 163 can be fed into the recovery sub-system 170 configured or adapted to receive and separate two or more products therefrom.
  • the recovery sub-system can be configured or adapted to obtain and discharge a naphtha stream via line 171, at least one olefin stream via line 172, and at least one hydrogen stream rich in hydrogen via line 174.
  • the recovery sub-system can also be configured or adapted to obtain and discharge the at least one paraffin stream rich in paraffins via line 173.
  • the paraffin stream in line 172 can include ethane, propane, butane, pentane, or any mixture thereof. In other examples, the paraffin stream in line 172 can include larger paraffins in addition to or in lieu of C2-C5 paraffins such as C6-C9 paraffins. [00115] Returning to the first flue gas stream in line 131, the first flue gas stream via line 131 and a quench medium via line 176 can be fed into an optional quenching section 180.
  • the quench medium in line 176 can be or can include an oxidizing agent, e.g., air.
  • a first portion of the oxidizing agent in line 101 can be fed into the optional heat exchange stage 105 and a second portion of the oxidizing agent in line 101 can be fed into the quenching section 180.
  • a cooled flue gas stream via line 181 can be discharged from the quenching section 180.
  • the flue gas stream via line 131 or the optionally cooled flue gas stream via line 181 can be fed into the further separation vessel 185 configured or adapted to receive and separate the flue gas stream or the cooled flue gas stream to obtain a second flue gas stream rich in the flue gas and a fourth particle stream rich in the particles.
  • the fourth separation vessel 185 can include one or more cyclones 186 (two are shown) configured or adapted to separate the flue gas stream or the cooled flue gas stream to obtain the second flue gas stream and fourth particle stream.
  • a stripping steam stream or fourth stripping steam stream (not shown) can be fed into the fourth separation vessel 185. If the stripping steam stream is fed into the fourth separation vessel 185, the stripping steam stream can improve or otherwise aid in separating the second flue gas and the fourth particle stream from the flue gas stream or the cooled flue gas stream.
  • the second flue gas stream can be discharged via line 108 from the fourth separation vessel 185.
  • the second flue gas stream can be or can make up at least a portion of the heat source or heated medium fed into the heat exchange stages 105, 106, and/or 107.
  • the fourth particle stream via line 187 can be discharged from the fourth separation vessel 185.
  • at least a portion of the fourth particle stream in line 187 can be removed via line 188 from the system 100.
  • the removal of at least a portion of the fourth particle stream via line 188 can be used to control or adjust an amount of particles in the system 100 that during operation can become undesirably rich in the transition metal element disposed thereon.
  • starter particles via line 124 can be fed into the combustion vessel 125, for example.
  • first, second, third, fourth, and fifth heat exchangers 105, 106, 107, 150, and 165 can be arranged or configured to receive the heat source or heated medium via line 108 in parallel, two or more could be integrated with one another, the heated medium fed thereto can be different heated mediums, etc.
  • the first, second, third, fourth, and fifth heat exchangers 105, 106, 107, 150, and 165 can each independently be or include any type or combination of heat exchanger.
  • the first, second, third, fourth, and fifth heat exchangers 105, 106, 107, 150, and 165 can independently be or include shell-and-tube heat exchanger, a plate and frame heat exchanger, brazed aluminum heat exchangers, a plate and fin heat exchanger, a spiral wound heat exchanger, a coil wound heat exchanger, a U-tube heat exchanger, a bayonet style heat exchanger, any other apparatus, or any combination thereof.
  • the separation vessels 120, 130, 140, and 185 can also be similarly configured in a number of ways.
  • the first and second quenching stages or quenching sections 135 and 155 can also be similarly configured in a number of ways.
  • a process for converting a hydrocarbon-containing feed by pyrolysis comprising: (I) feeding the hydrocarbon-containing feed into a pyrolysis reaction zone; (II) feeding a plurality of fluidized particles having a first temperature into the pyrolysis reaction zone, wherein the first temperature is sufficiently high to enable pyrolysis of at least a portion of the hydrocarbon-containing feed on contacting the particles, and the particles comprise an oxide of a transition metal element capable of oxidizing molecular hydrogen (Fh) at the first temperature; and (III) contacting at least a portion of the hydrocarbon-containing feed with the particles in the pyrolysis reaction zone to effect pyrolysis of at least a portion of the hydrocarbon-containing feed to produce a pyrolysis effluent comprising olefins, hydrogen, and the particles, wherein at least a portion of the transition metal element in the particles in the pyrolysis effluent is
  • transition metal element is selected from oxides of titanium, vanadium, chromium, manganese, iron, cobalt, niobium, nickel, molybdenum, tantalum, tungsten, alloys thereof, and mixtures thereof.
  • A3 The process of A2, wherein the transition metal element is selected from oxides of vanadium, chromium, manganese, iron, cobalt, nickel, and mixtures thereof.
  • A4 The process of Al to A3, wherein the oxide of the transition metal element has a concentration in a range from 500 ppmw to 50 wt%, based on the total weight of the particles. [00124] A5. The process of any of Al to A4, wherein the oxide of the transition metal element favors the oxidation of molecular hydrogen over the combustion of hydrocarbons contained in the pyrolysis reaction zone.
  • A6 The process of any of Al to A5, wherein the particles comprise inert cores and a surface layer comprising the oxide of the transition metal element.
  • A7 The process of A6, wherein the inert cores comprise silica, alumina, zirconia, and mixtures and combinations thereof.
  • A8 The process of any of Al to A7, wherein the hydrocarbon-containing feed comprises the transitional metal element contained in the particles, and at least a portion of the transition metal element contained in the particles is derived from the metal element contained in the hydrocarbon-containing feed.
  • any of Al to A10 further comprising: (IV) optionally steam stripping the pyrolysis effluent using a first stripping steam stream; (V) obtaining from the pyrolysis effluent and the optional first stripping steam stream a first hydrocarbon stream rich in hydrocarbons and a first particle stream rich in the particles; (VI) oxidizing and heating at least a portion of the particles in the first particle stream in a combustion zone such that at least a portion of the transition metal element in the particles is oxidized to a higher oxidation state compared to the transition metal element in the particles in the pyrolysis effluent; and (VII) feeding at least a portion of the heated and oxidized particles to the pyrolysis reaction zone as at least a portion of the particles fed into the pyrolysis reaction zone in step (II). [00131] A12. The process of A11, wherein step (IV) is performed.
  • step (VI) steam stripping at least a portion of the heated and oxidized particles.
  • step (VI) a combustion zone effluent comprising the heated and oxidized particles and a flue gas is produced, and the process further comprise, after step (VI) and before step (VII), the following steps: (VIb) separating the combustion zone effluent into a second particle stream rich in the heated and oxidized particles and a first flue gas stream rich in the flue gas; (Vic) separating the particles, if any, contained in the first flue gas stream using a cyclone; and (VId) feeding at least a portion of the particles separated in step (Vic) to the combustion zone.
  • A15 The process of any of All to A14, wherein at least a portion of the particles fed into the pyrolysis reaction zone in step (II) is formed by: (VIII) feeding a plurality of starter particles into the pyrolysis reaction zone; (IX) feeding a source material for the transition metal element into the pyrolysis reaction zone; (X) contacting the starter particles with the source material for the transition metal element in the pyrolysis reaction zone to obtain a contacting mixture effluent comprising the starter particles having a layer of the source material for the transition metal element deposited thereon; and (XI) heating and oxidizing at least a portion of the starter particles having the layer of the source material for the transition metal element in the combustion zone to form the particles comprising the transition metal element.
  • A16 The process of A15, wherein the source material for the transition metal element in step (IX) is present in the hydrocarbon-containing feed.
  • A18 The process of any of A15 or A17, wherein at least a portion of the starter particles are derived from a fluid catalytic converter catalyst.
  • step (VI) oxidizing and heating the at least a portion of the particles in the first particle stream in the combustion zone is done in the presence of an oxidizing agent.
  • A20 The process of A19, wherein a feeding rate of the oxidizing agent introduced into the combustion zone is adjusted so that the flue gas contains at least 1 mol% of carbon monoxide.
  • A21 The process of A 19, wherein a feeding rate of the oxidizing agent introduced into the combustion zone is adjusted so that the flue gas contains at least a portion of the oxidizing agent and less than 1 mol% of carbon monoxide.
  • step (III) coke is formed on the surface of the particles, and in step (VI), at least a portion of the coke on the surface of the particles is combusted.
  • A23 The process of any of A1 to A22, wherein the hydrocarbon-containing feed comprises a resid.
  • A24 The process of any of A1 to A23, wherein the first temperature is in a range from 800°C to 1400°C.
  • A25 The process of any of A1 to A24, wherein the hydrocarbon-containing feed has a temperature in a range from 100°C to 400°C.
  • A26 The process of any of A1 to A25, further comprising (la) feeding steam into the pyrolysis reaction zone.
  • A27 The process of A26, wherein the weight ratio of the steam fed into the pyrolysis reaction zone to the hydrocarbon-containing feed is in a range from 0.2:1 to 1:1.
  • A28 The process of any of A1 to A27 wherein the contacting in the pyrolysis reaction zone in step (III) has a residence time from 10 milliseconds to 500 milliseconds.
  • A29 The process of any of A1 to A28, wherein the contacting in the pyrolysis reaction zone in step (III) is performed under an absolute pressure from 101 to 800 kPa.
  • A30 The process of any of A1 to A29, wherein the pyrolysis effluent has a temperature in a range from 800°C to 1,200°C upon exiting the pyrolysis reaction zone.
  • A31 The process of any of A1 to A30, wherein the pyrolysis reaction zone is located in a downflow reactor.
  • A32 The process of any of All to A31, further comprising: (XII) quenching the first hydrocarbon stream.
  • A33 The process of A32, wherein the first hydrocarbon stream has a temperature in a range from 650°C to 1,200°C immediately before quenching.
  • A34 The process of A32 or A33, wherein the time from the contacting in step (III) in the pyrolysis reactor to the quenching in step (XII) is in a range from 10 to 2000 milliseconds.
  • A35 The process of any of A32 to A34, wherein step (XII) comprises contacting the hydrocarbon stream with a quench medium to produce a cooled hydrocarbon stream.
  • A36 The process of A35, wherein the quench medium comprises a stream rich in paraffins.
  • A37 The process of A36, and wherein the first hydrocarbon stream is at a temperature sufficient to effect pyrolysis of at least a portion of the stream rich in paraffins.
  • A38 The process of any of A35 to A37, wherein the first hydrocarbon stream is at a temperature of 650°C to 1,100°C when initially contacted with the quench medium.
  • C2-C9 alkanes and wherein at least 1 wt% of the one or more C2-C9 alkanes in the quench medium is pyrolyzed to produce olefins, aromatic hydrocarbons, or a mixture thereof.
  • A40 The process of any of A32 to A39, further comprising: (XIII) separating the quenched first hydrocarbon stream to obtain a second hydrocarbon stream rich in hydrocarbons and a third particle stream rich in the particles; and (XIV) recycling at least a portion of the particles in the third particle stream to the combustion zone.
  • A41 The process of any of A40, further comprising: (XV) obtaining from the second hydrocarbon stream a gas oil stream and a bottoms heavy stream.
  • A42 The process of A41, further comprising at least one of the following steps:
  • A43 The process of A41 or A42, further comprising: (XVII) obtaining from the second hydrocarbon stream at least one of the following: (i) a naphtha stream, (ii) an olefin stream rich in an olefin, and (iii) a stream rich in hydrogen.
  • A44 The process of any of A1 to A43, wherein the hydrocarbon-containing feed is produced by: (la) feeding a raw feed into a flashing drum; (lb) obtaining an overhead vapor effluent and a bottoms liquid effluent from the flashing drum; and (Ic) obtaining the hydrocarbon-containing feed from the bottoms liquid effluent.
  • A45 The process of A44, wherein the raw feed comprises a crude, an atmospheric resid, and/or a vacuum resid.
  • A46 The process of A44 or A45, wherein a cutoff point of the bottoms liquid effluent is from 300°C to 700°C.
  • A47 The process of any of A44 to A46, further comprising feeding at least a portion of the overhead vapor effluent to a steam cracker.
  • a process for converting a hydrocarbon-containing feed by pyrolysis comprising: (I) feeding the hydrocarbon-containing feed to a pyrolysis reaction zone, wherein the hydrocarbon-containing feed comprises a first transition metal element; (II) feeding a plurality of fluidized particles having a first temperature into the pyrolysis reaction zone, wherein the first temperature is sufficiently high to enable pyrolysis of at least a portion of the hydrocarbon-containing feed on contacting the particles, and the particles comprise an oxide of a second transition metal element capable of oxidizing molecular hydrogen (3 ⁇ 4) at the first temperature; (III) contacting at least a portion of the hydrocarbon-containing feed with the particles in the pyrolysis reaction zone to effect pyrolysis of at least a portion of the hydrocarbon-containing feed to produce a pyrolysis effluent comprising olefins, hydrogen, and the particles, wherein at least a portion of the second transition metal element in the particles in the pyrolysis efflu
  • B2 The process of Bl, wherein the oxide of the second transition metal element favors the oxidation of molecular hydrogen over the combustion of hydrocarbons contained in the pyrolysis reaction zone.
  • B3 The process of B 1 or B2, wherein oxidizing and heating the at least a portion of the particles in the first particle stream in the combustion zone oxidizes at least a portion of the first transition metal element deposited on the particles to a higher oxidation state compared to the first transition metal element on the particles in the pyrolysis effluent.
  • B6 The process of B5, wherein the first hydrocarbon stream is at a temperature sufficient to effect pyrolysis of at least a portion of the one or more paraffins in the stream rich in paraffins.
  • B7 The process of any of B4 to B6, wherein the first hydrocarbon stream is at a temperature of 650°C to 1,100°C when initially contacted with the quench medium.
  • B8 The process of B6 or B7, wherein at least 1 wt% of the one or more C2-C9 alkanes in the quench medium is pyrolyzed to produce olefins, aromatic hydrocarbons, or a mixture thereof.
  • B10 The process of any of B1 to B9, wherein the oxide of the second transition metal element has a concentration in a range from 500 ppmw to 50 wt%, based on the total weight of the particles.
  • Bll The process of any of B1 to B10, wherein the particles comprise inert cores and a surface layer comprising the oxide of the second transition metal element.
  • B12 The process of any of B1 to B12, wherein the inert cores comprise silica, alumina, zirconia, and mixtures or combinations thereof.
  • B13 The process of any of B1 to B12, wherein the weight ratio of the particles to the hydrocarbon-containing feed is in a range from 10:1 to 50:1, preferably from 15:1 to 50:1, more preferably from 20:1 to 50:1.
  • B14 The process of any of B1 to B13, wherein the particles have an average size in a range from 25 to 500 micrometers.
  • B 15 The process of any of B 1 to A 14, wherein at least a portion of the particles are derived from a fluid catalytic converter catalyst.
  • step (III) coke is formed on the surface of the particles, and in step (VI), at least a portion of the coke on the surface of the particles is combusted.
  • B17 The process of any of B1 to B16, wherein the hydrocarbon-containing feed comprises a resid.
  • B18 The process of any of B1 to B17, wherein the contacting in the pyrolysis reaction zone in step (III) has a residence time from 10 milliseconds to 500 milliseconds.
  • B19 The process of any of B1 to B18, wherein the hydrocarbon-containing feed is produced by: (la) feeding a raw feed into a flashing drum; (lb) obtaining an overhead vapor effluent and a bottoms liquid effluent from the flashing drum; and (Ic) obtaining the hydrocarbon-containing feed from the bottoms liquid effluent.
  • B20 The process of B19, wherein the raw feed comprises a crude, an atmospheric resid, and/or a vacuum resid.
  • B21 The process of B 19 or B20, wherein a cutoff point of the bottoms liquid effluent is from 300°C to 700°C.
  • B22 The process of any of B19 to B21, further comprising feeding at least a portion of the overhead vapor effluent to a steam cracker.
  • step (VI) oxidizing and heating the at least a portion of the particles in the first particle stream in the combustion zone is done in the presence of an oxidizing agent.
  • B24 The process of B23, wherein a feeding rate of the oxidizing agent introduced into the combustion zone is adjusted so that the flue gas contains at least 1 mol% of carbon monoxide.
  • a system for converting a hydrocarbon-containing feed by pyrolysis comprising: (i) a pyrolysis reactor adapted for receiving the hydrocarbon-containing feed and a fluidized stream of particles having a first temperature, and allowing the hydrocarbon- containing feed to contact the particles to effect pyrolysis of at least a portion of the hydrocarbon-containing feed, wherein the first temperature is sufficiently high to enable pyrolysis of at least a portion of the hydrocarbon-containing feed, and wherein the particles comprise an oxide of a transition metal element capable of oxidizing molecular hydrogen (3 ⁇ 4) at the first temperature, and discharging a pyrolysis effluent; (ii) a first separation vessel adapted for receiving the pyrolysis effluent, optionally receiving a stripping steam stream, separating the pyrolysis effluent to obtain a first hydrocarbon stream rich in hydrocarbons and a first particle stream rich in the particles, discharging the first hydrocarbon stream, and discharging the first particle
  • C5. The system of any of Cl to C4, further comprising: (vi) a quenching section downstream of the first separation vessel adapted for receiving the first hydrocarbon stream, receiving a stream of a quenching medium, and discharging a quenched mixture stream comprising the quenching medium and the first hydrocarbon stream; (vii) a third separation vessel comprising a cyclone, wherein the third separation vessel is adapted for receiving the quenched mixture stream, separating the quenched mixture stream to obtain a third particle stream rich in the particles and a second hydrocarbon stream rich in hydrocarbons, discharging the third particle stream, and discharging the second hydrocarbon stream; and (viii) a channel adapted for feeding at least a portion of the third particle stream to the first separation vessel or to the combustion vessel.
  • C6 The system of any of Cl to C5, further comprising: (ix) an optional heat exchanger adapted for receiving the second hydrocarbon stream, cooling the second hydrocarbon stream rich in hydrocarbons, and discharging a cooled second hydrocarbon stream rich in hydrocarbons; (x) a distillation column adapted for receiving the second hydrocarbon stream or the optionally cooled second hydrocarbon stream, separating the second hydrocarbon stream to obtain a bottoms heavy oil stream, and a side-draw gas oil stream.
  • an optional heat exchanger adapted for receiving the second hydrocarbon stream, cooling the second hydrocarbon stream rich in hydrocarbons, and discharging a cooled second hydrocarbon stream rich in hydrocarbons
  • a distillation column adapted for receiving the second hydrocarbon stream or the optionally cooled second hydrocarbon stream, separating the second hydrocarbon stream to obtain a bottoms heavy oil stream, and a side-draw gas oil stream.
  • C8 The system of C6 or C7, further comprising: (xii) a channel adapted for feeding at least a portion of the bottoms heavy oil stream to the combustion zone as at least a portion of the fuel.
  • C9 The system of any of C6 to C8, wherein the distillation column is further adapted for discharging an overhead stream rich in naphtha and light hydrocarbons, and the system further comprises: (xiii) a recovery sub-system adapted for receiving the overhead stream, separating the overhead stream, discharging a naphtha stream, discharging at least one olefin stream rich in an olefin, and discharging at least one hydrogen stream rich in hydrogen. [00201] CIO.
  • any of Cl to C9 further comprising: (xiv) a fourth separation vessel comprising a cyclone, wherein the fourth separation vessel is adapted for receiving the first flue gas stream, separating the first flue gas stream to obtain a second flue gas stream rich in the flue gas and a fourth particle stream rich in the particles, discharging the second flue gas stream, and discharging the fourth particle stream; and (xv) a channel adapted for feeding at least a portion of the fourth particle stream to the combustion vessel.
  • Cll The system of CIO, further comprising: a heat exchanger adapted for heating the hydrocarbon-containing feed to produce a heated hydrocarbon-containing feed by transferring heat from the second flue gas stream rich in the flue gas to the hydrocarbon- containing feed; and a channel adapted for feeding at least a portion of the second flue gas stream into the heat exchanger adapted for heating the hydrocarbon-containing feed.

Abstract

L'invention concerne des procédés et des systèmes de valorisation d'une charge contenant des hydrocarbures. La charge contenant des hydrocarbures et une pluralité de particules fluidisées peuvent être introduites dans une zone de réaction de pyrolyse. La pluralité de particules fluidisées peut avoir une première température qui peut être suffisamment élevée pour permettre la pyrolyse d'au moins une partie de la charge contenant des hydrocarbures lors de la mise en contact des particules. Les particules peuvent comprendre un oxyde d'un élément de métal de transition capable d'oxyder l'hydrogène moléculaire à la première température. La charge contenant des hydrocarbures peut être mise en contact avec les particules dans la zone de réaction de pyrolyse pour effectuer la pyrolyse d'au moins une partie de la charge contenant des hydrocarbures pour produire un effluent de pyrolyse. Au moins une partie de l'élément de métal de transition dans les particules contenues dans l'effluent de pyrolyse peut être à un état réduit par rapport à l'élément de métal de transition dans les particules introduites dans la zone de réaction de pyrolyse.
PCT/US2020/044137 2019-08-02 2020-07-30 Procédés et systèmes de valorisation d'une charge contenant des hydrocarbures WO2021025930A1 (fr)

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