WO2022136976A1 - Systems and methods for steam cracking hydrocarbons - Google Patents
Systems and methods for steam cracking hydrocarbons Download PDFInfo
- Publication number
- WO2022136976A1 WO2022136976A1 PCT/IB2021/060935 IB2021060935W WO2022136976A1 WO 2022136976 A1 WO2022136976 A1 WO 2022136976A1 IB 2021060935 W IB2021060935 W IB 2021060935W WO 2022136976 A1 WO2022136976 A1 WO 2022136976A1
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- WIPO (PCT)
- Prior art keywords
- pyrolysis oil
- steam
- polymer composite
- steam cracker
- composite tubes
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 72
- 238000004230 steam cracking Methods 0.000 title claims abstract description 43
- 229930195733 hydrocarbon Natural products 0.000 title claims abstract description 35
- 150000002430 hydrocarbons Chemical class 0.000 title claims abstract description 35
- 239000002131 composite material Substances 0.000 claims abstract description 31
- 229920000642 polymer Polymers 0.000 claims abstract description 31
- 239000004215 Carbon black (E152) Substances 0.000 claims abstract description 28
- 238000000197 pyrolysis Methods 0.000 claims description 53
- 238000012545 processing Methods 0.000 claims description 18
- -1 polyphenylene Polymers 0.000 claims description 17
- 238000000746 purification Methods 0.000 claims description 15
- 125000005842 heteroatom Chemical group 0.000 claims description 13
- 150000001336 alkenes Chemical class 0.000 claims description 11
- 239000004698 Polyethylene Substances 0.000 claims description 10
- 229920000573 polyethylene Polymers 0.000 claims description 10
- 239000000356 contaminant Substances 0.000 claims description 9
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 7
- 239000003546 flue gas Substances 0.000 claims description 7
- 239000004721 Polyphenylene oxide Substances 0.000 claims description 6
- 229920006380 polyphenylene oxide Polymers 0.000 claims description 6
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 6
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 6
- 229920002981 polyvinylidene fluoride Polymers 0.000 claims description 6
- 238000001179 sorption measurement Methods 0.000 claims description 5
- 229920000265 Polyparaphenylene Polymers 0.000 claims description 4
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 claims description 4
- 239000004417 polycarbonate Substances 0.000 claims description 3
- 229920000515 polycarbonate Polymers 0.000 claims description 3
- 229920003023 plastic Polymers 0.000 description 10
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- 229920000139 polyethylene terephthalate Polymers 0.000 description 4
- 239000005020 polyethylene terephthalate Substances 0.000 description 4
- 229920001155 polypropylene Polymers 0.000 description 4
- 230000005855 radiation Effects 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- VQTUBCCKSQIDNK-UHFFFAOYSA-N Isobutene Chemical compound CC(C)=C VQTUBCCKSQIDNK-UHFFFAOYSA-N 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- IAQRGUVFOMOMEM-UHFFFAOYSA-N but-2-ene Chemical compound CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- ZSWFCLXCOIISFI-UHFFFAOYSA-N cyclopentadiene Chemical compound C1C=CC=C1 ZSWFCLXCOIISFI-UHFFFAOYSA-N 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000000116 mitigating effect Effects 0.000 description 2
- 239000004632 polycaprolactone Substances 0.000 description 2
- 239000004800 polyvinyl chloride Substances 0.000 description 2
- 229920006395 saturated elastomer Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- PMJHHCWVYXUKFD-SNAWJCMRSA-N (E)-1,3-pentadiene Chemical compound C\C=C\C=C PMJHHCWVYXUKFD-SNAWJCMRSA-N 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- PXGOKWXKJXAPGV-UHFFFAOYSA-N Fluorine Chemical compound FF PXGOKWXKJXAPGV-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000012993 chemical processing Methods 0.000 description 1
- 239000000460 chlorine Substances 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 239000000306 component Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 150000001993 dienes Chemical class 0.000 description 1
- XNMQEEKYCVKGBD-UHFFFAOYSA-N dimethylacetylene Natural products CC#CC XNMQEEKYCVKGBD-UHFFFAOYSA-N 0.000 description 1
- 229910052731 fluorine Inorganic materials 0.000 description 1
- 239000011737 fluorine Substances 0.000 description 1
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 230000005764 inhibitory process Effects 0.000 description 1
- 150000002484 inorganic compounds Chemical class 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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- 125000001477 organic nitrogen group Chemical group 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000013502 plastic waste Substances 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
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
- C10G9/34—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
-
- 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
- C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
- C10G45/02—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
-
- 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
- C10G55/00—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process
- C10G55/02—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process plural serial stages only
- C10G55/04—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process plural serial stages only including at least one thermal cracking step
-
- 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
- C10G69/00—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process
- C10G69/02—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process plural serial stages only
- C10G69/06—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process plural serial stages only including at least one step of thermal cracking in the absence of hydrogen
-
- 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
- C10G75/00—Inhibiting corrosion or fouling in apparatus for treatment or conversion of hydrocarbon oils, in general
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
- C10G9/14—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils in pipes or coils with or without auxiliary means, e.g. digesters, soaking drums, expansion means
- C10G9/18—Apparatus
- C10G9/20—Tube furnaces
- C10G9/203—Tube furnaces chemical composition of the tubes
-
- 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
- C10G2300/20—Characteristics of the feedstock or the products
- C10G2300/201—Impurities
- C10G2300/202—Heteroatoms content, i.e. S, N, O, P
-
- 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
- C10G2300/4006—Temperature
-
- 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
-
- 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
- C10G2400/30—Aromatics
Definitions
- the present invention generally relates to systems and methods for steam cracking hydrocarbons. More specifically, the present invention relates to systems and methods for steam cracking hydrocarbons using a steam cracking unit that uses polymer composite tubes in the convection section.
- Steam cracking is one of the most commonly used processes for producing light olefins and other high valued chemicals in the chemical industry.
- feedstock to be cracked and high pressure steam are preheated in a convection section, which comprises a series of tube bundles, via indirect convective heat transfer from flue gas to feedstock and the high pressure steam.
- the hydrocarbons in the preheated feedstock and steam mixture are then cracked in the radiation section of the steam cracker.
- the solution resides in a steam cracking unit that comprises polymer composite tubes in the convection section.
- This can be beneficial as the polymer composite material(s) used for making the tubes are configured to reduce the fouling rate in the tubes, thereby mitigating the fouling issue in the convection sections of steam crackers and reducing the frequency of cleaning of fouling from the steam crackers. Consequently, the disclosed systems and methods are capable of improving the production efficiency of the steam crackers. Therefore, the disclosed systems and methods of the present invention provide a technical solution to the problem associated with the conventional systems and methods for steam cracking.
- Embodiments of the invention include a method of processing a hydrocarbon stream.
- the method comprises steam-cracking the hydrocarbon stream in a steam cracker comprising a convection section that comprises one or more polymer composite tubes.
- Embodiments of the invention include a method of processing a pyrolysis oil stream.
- the method comprises removing heteroatom contaminants from the pyrolysis oil stream in a purification unit to produce a purified pyrolysis oil.
- the method comprises steamcracking the purified pyrolysis oil stream in a steam cracker to produce olefins and aromatics.
- the steam cracker comprises a convection section that includes one or more polymer composite tubes.
- Embodiments of the invention include a method of processing a pyrolysis oil stream.
- the method comprises removing heteroatom contaminants from the pyrolysis oil stream in a purification unit to produce a purified pyrolysis oil.
- the method comprises steamcracking the purified pyrolysis oil stream in a steam cracker to produce olefins and aromatics.
- the steam cracker comprises a feed preheater bank that comprises one or more polymer composite tubes.
- wt.% refers to a weight, volume, or molar percentage of a component, respectively, based on the total weight, the total volume, or the total moles of material that includes the component.
- 10 moles of component in 100 moles of the material is 10 mol.% of component.
- primarily means greater than any of 50 wt.%, 50 mol.%, and 50 vol.%.
- “primarily” may include 50.1 wt.% to 100 wt.% and all values and ranges there between, 50.1 mol.% to 100 mol.% and all values and ranges there between, or 50.1 vol.% to 100 vol.% and all values and ranges there between.
- FIG. 1 shows a schematic diagram of a system for processing a hydrocarbon stream, according to embodiments of the invention
- FIG. 2 shows a schematic diagram of a convection section of a steam cracking furnace, according to embodiments of the invention.
- FIG. 3 shows a schematic flowchart of a method of processing a hydrocarbon stream, according to embodiments of the invention.
- the present invention provides a solution to this problem.
- the solution is premised on a steam cracking system comprising polymer composite tubes in the convection section thereof and a method of processing a hydrocarbon stream using the steam cracking system.
- the polymer composite tubes are configured to mitigate fouling of the convection section of the steam cracker, thereby reducing the time needed to remove fouling and improving overall efficiency of the steam cracker.
- the system for processing a hydrocarbon stream is capable of reducing fouling in a convection section of a steam cracker, thereby improving the production efficiency of the steam cracker.
- FIG. 1 a schematic diagram is shown for system 100, which is used for processing a hydrocarbon stream.
- system 100 includes purification unit 101 configured to purify hydrocarbon stream 11 to produce purified hydrocarbon stream 12.
- Hydrocarbon stream 11 can include a pyrolysis oil stream derived from pyrolysis of plastics.
- the plastics include polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polycaprolactone (PCL/nylon-like plastic), or combinations thereof.
- the pyrolysis oil stream can include heteroatoms including organic nitrogen, organic chlorine, oxygenates, silicone, fluorine, phosphorous, or combinations thereof.
- the pyrolysis oil stream can further include 10 to 50 wt.% unsaturated hydrocarbons.
- Purified hydrocarbon stream 12 can include a purified pyrolysis oil stream. Purified hydrocarbon stream 12 may include less than 0.1 wt.% heteroatoms. Purified hydrocarbon stream 12 may include 1 to 50 wt.% unsaturated hydrocarbons. In embodiments of the invention, purification unit 101 is configured to remove the heteroatoms from the pyrolysis oil stream. Purification unit 101 may be further configured to remove at least some fines, particles from the pyrolysis oil stream. In embodiments of the invention, purification unit 101 can include an adsorption unit, a hydrotreatment unit, or combinations thereof.
- system 100 includes steam cracking unit 102 configured to steam crack purified hydrocarbon stream 12 to produce cracked stream 13 comprising olefins and/or aromatics.
- steam cracking unit 102 comprises one or more steam cracking furnaces. Each steam cracking furnace can include a convection section and a radiation section.
- the convection section of a steam cracking furnace comprises one or more polymer composite tubes. The polymer composite tubes can be in bundles.
- the polymer composite tubes can comprise a polymer composite material comprising polyphenylene sulphide (PPS), polyvinylidene difluoride (PVDF), polytetrafluoroethylene (PTFE), polyethylene (PE), polycarbonate (PC), polyphenylene oxide (PPO), perfluoroalcoxy (PF A), or combinations thereof.
- PPS polyphenylene sulphide
- PVDF polyvinylidene difluoride
- PTFE polytetrafluoroethylene
- PE polyethylene
- PC polycarbonate
- PPO polyphenylene oxide
- PF A perfluoroalcoxy
- the polymer composite tubes comprises polyphenylene sulphide and the composite tubes may have an operating temperature limit of 20 to 300 °C and all ranges and values there between including ranges of 20 to 40 °C, 40 to 60 °C, 60 to 80 °C, 80 100 °C, 100 to 120 °C, 120 to 140 °C, 140 to 160 °C, 160 to 180 °C, 180 to 200 °C, 200 to 220 °C, 220 to 240 °C, 240 to 260 °C, 260 to 280 °C, and 280 to 300 °C.
- the convection section is configured to prepare feedstock (e.g., purified hydrocarbon stream 12) for cracking in the radiation section.
- the convection section of the steam cracking furnace can include feed preheater bank 201, upper mixed preheater bank 202, and lower mixed preheater bank 203.
- feed preheater bank 201 is configured to heat purified hydrocarbon stream 12 (e.g., the pyrolysis oil stream derived from plastics) to a first temperature.
- the first temperature is in a range of 60 to 150 °C and all ranges and values there between including ranges of 60 to 70 °C, 70 to 80 °C, 80 to 90 °C, 90 to 100 °C, 100 to 110 °C, 110 to 120 °C, 120 to 130 °C, 130 to 140 °C, and 140 to 150 °C.
- Upper mixed preheater bank 202 may be configured to heat a mixture of (1) the preheated purified hydrocarbon stream 12 from feed preheater bank 201 and (2) steam to a second temperature.
- the second temperature is in a range of 150 to 230 °C and all ranges and values there between including ranges of 150 to 160 °C, 160 to 170 °C, 170 to 180 °C, 180 to 190 °C, 190 to 200 °C, 200 to 210 °C, 210 to 220 °C, and 220 to 230 °C.
- lower mixed preheater bank 203 is configured to further heat the mixture from upper mixed preheater bank 202 to a third temperature.
- the third temperature may be in a range of 300 to 600 °C and all ranges and values there between including ranges of 300 to 330 °C, 330 to 360 °C, 360 to 390 °C, to 390 to 420 °C, 420 to 450 °C, 450 to 480 °C, 480 to 510 °C, 510 to 540 °C, 540 to 570 °C, and 570 to 600 °C.
- feed preheater bank 201, uppermixed preheater bank 202, and/or lower mixed preheater bank 203 are heated using flue gas from the radiation section of the steam cracking furnace.
- the flue gas in feed preheater bank 201 is at a temperature of 140 to 260 °C and all ranges and values there between 140 to 150 °C, 150 to 160 °C, 160 to 170 °C, 170 to 180 °C, 180 to 190 °C, 190 to 200 °C, 200 to 210 °C, 210 to 220 °C, 220 to 230 °C, 230 to 240 °C, 240 to 250 °C, and 250 to 260 °C.
- the flue gas in upper mixed preheater bank 202 is at a temperature of 420 to 550 °C and all ranges and values there between including ranges of 420 to 430 °C, 430 to 440 °C, 440 to 450 °C, 450 to 460 °C, 460 to 470 °C, 470 to 480 °C, 480 to 490 °C, 490 to 500 °C, 500 to 510 °C, 510 to 520 °C, 520 to 530 °C, 530 to 540 °C, and 540 to 550 °C.
- the flue gas in lower mixed preheater bank 203 is at a temperature of 760 to 1140 °C and all ranges and values there between including ranges of 760 to 790 °C, 790 to 820 °C, 820 to 850 °C, 850 to 880 °C, 880 to 910 °C, 910 to 940 °C, 940 to 970 °C, 970 to 1000 °C, 1000 to 1030 °C, 1030 to 1060 °C, 1060 to 1090 °C, 1090 to 1120 °C, and 1120 to 1140 °C.
- feed preheater bank 201 comprises one or more of the polymer composite tubes.
- a method of processing a hydrocarbon stream, including a pyrolysis oil stream derived from plastics is described. As shown in FIG. 3, embodiments of the invention include method 300 for processing a pyrolysis oil derived from plastics. Method 300 may be implemented by system 100, as shown in FIG. 1, and described above.
- method 300 includes removing, in purification unit 101, heteroatom contaminants from pyrolysis oil of hydrocarbon stream 11 to produce purified pyrolysis oil of purified hydrocarbon stream 12.
- the pyrolysis oil is produced from pyrolyzing plastics.
- the plastics may include plastic waste.
- Exemplary plastics used for producing the pyrolysis oil can include polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polycaprolactone (PCL/nylon-like plastic), or combinations thereof.
- the pyrolysis oil comprises 1000 to 50000 ppm heteroatoms, collectively.
- the purified pyrolysis oil can comprise 100 to 1000 ppm heteroatoms.
- purification unit 101 includes an adsorption unit, and/or a hydrotreatment unit.
- the adsorption unit is configured to remove contaminants, and/or remove at least some unsaturated compounds.
- the hydrotreament unit can be configured to convert contaminants into inorganic compounds for removal in subsequent processes, and/or convert unsaturated compounds to saturated compounds using hydrogen.
- Pyrolysis oil at block 301 can include 10 to 50 wt.% unsaturated hydrocarbons.
- Purified pyrolysis oil in embodiments of the invention, can comprise 1 to 50 wt.% unsaturated hydrocarbons.
- purification unit 101 is configured to remove substantially no unsaturated hydrocarbons from the pyrolysis oil.
- Purification unit 101, at block 301 can be operated at an operating temperature of 350 to 450 °C.
- Purification unit 101, at block 301 can be operated at an operating pressure of 40 to 130 bar.
- method 300 includes steam-cracking, in steam cracking unit 102, the purified pyrolysis oil to produce olefins and aromatics.
- one or more steam cracking furnaces of steam cracking unit 102 comprise the polymer composite tubes configured to reduce fouling rate in the convection section of the steam cracking furnace.
- the fouling in the convection section can include one or more polymers, coke, polystyrene, indienes, cyclopentadiene, or combinations thereof.
- the polymer composite tubes are in the convection section of the one or more steam cracking furnaces.
- the polymer composite tubes can be in the feed preheater bank 201 of the one or more steam cracking furnaces.
- the feed pre-heater is operated at a temperature of 140 to 260 °C and all ranges and values there between including ranges of 140 to 150 °C, 150 to 160 °C, 160 to 170 °C, 170 to 180 °C, 180 to 190 °C, 190 to 200 °C, 200 to 210 °C, 210 to 220 °C, 220 to 230 °C, 230 to 240 °C, 240 to 250 °C, and 250 to 260 °C.
- the pyrolysis oil is cracked at a temperature of 800 to 850 °C and all ranges and values there between including ranges of 800 to 805 °C, 805 to 810 °C, 810 to 815 °C, 815 to 820 °C, 820 to 825 °C, 825 to 830 °C, 830 to 835 °C, 835 to 840 °C, 840 to 845 °C, and 845 to 850 °C.
- the steam cracking unit 102 is operated at a residence time of 10 to 700 ms and all ranges and values there between including ranges of 10 to 50 ms, 50 to 100 ms, 100 to 150 ms, 150 to 200 ms, 200 to 250 ms, 250 to 300 ms, 300 to 350 ms, 350 to 400 ms, 400 to 450 ms, 450 to 500 ms, 500 to 550 ms, 550 to 600 ms, 600 to 650 ms, and 650 to 700 ms.
- the steam-cracking is performed at a steam-to-hydrocarbon weight ratio of 0.35 to 1.0 and all ranges and values there between including ranges of 0.35 to 0.40, 0.40 to 0.45, 0.45 to 0.50, 0.50 to 0.55, 0.55 to 0.60, 0.60 to 0.65, 0.65 to 0.70, 0.70 to 0.75, 0.75 to 0.80, 0.80 to 0.85, 0.85 to 0.90, 0.90 to 0.95, and 0.95 to 1.0.
- the pyrolysis oil is cracked at a conversion rate of 50 to 100% and all ranges and values there between including ranges of 50 to 60%, 60 to 70%, 70 to 80%, 80 to 90%, and 90 to 100%.
- the conversation rate of the pyrolysis oil is dependent on percentages of aromatics in the pyrolysis oil.
- the pyrolysis oil can include 100 wt.% paraffins and the conversion rate of the pyrolysis oil can be substantially 100%.
- the produced olefins can include ethylene, propylene, 1-butene, 2-butene, isobutene, butadiene, pentadiene, or combinations thereof.
- the produced aromatics can include benzene, toluene, xylene, styrene, or combinations thereof.
- the systems and processes described herein can also include various equipment that is not shown and is known to one of skill in the art of chemical processing. For example, some controllers, piping, computers, valves, pumps, heaters, thermocouples, pressure indicators, mixers, heat exchangers, and the like may not be shown.
- Embodiment 1 is a method of processing a hydrocarbon stream.
- the method includes steam-cracking the hydrocarbon stream in a steam cracker including a convection section that includes one or more polymer composite tubes.
- Embodiment 2 is a method of processing a pyrolysis oil stream.
- the method includes removing heteroatom contaminants from the pyrolysis oil stream in a purification unit to produce a purified pyrolysis oil.
- the method further includes steam-cracking the purified pyrolysis oil stream in a steam cracker to produce olefins and aromatics, wherein the steam cracker includes a convection section that includes one or more polymer composite tubes.
- Embodiment 3 is the method of any of embodiments 1 and 2, wherein the convection section includes a feed preheater of the steam cracker.
- Embodiment 4 is the method of any of embodiments 1 to 3, wherein the feed pre-heater is operated at a temperature of 140 to 260 °C.
- Embodiment 5 is the method of any of embodiments 1 to 4, wherein the feed pre-heater is heated by a flue gas generated in a radiant section of the steam cracker.
- Embodiment 6 is the method of any of embodiments 1 to 5, wherein the polymer composite tubes contain polyphenylene sulphide (PPS), polyvinylidene difluoride (PVDF), polytetrafluoroethylene (PTFE), polyethylene (PE), polycarbonate (PC), polyphenylene oxide (PPO), perfluoroalcoxy (PF A), or combinations thereof.
- PPS polyphenylene sulphide
- PVDF polyvinylidene difluoride
- PTFE polytetrafluoroethylene
- PE polyethylene
- PC polycarbonate
- PPO polyphenylene oxide
- PF A perfluor
- Embodiment 7 is the method of any of embodiments 1 to 6, wherein the polymer composite tubes have an operating temperature limit of 20 to 300 °C.
- Embodiment 8 is the method of any of embodiments 1 to 7, wherein the purifying unit includes an adsorption unit, a hydrotreatment unit.
- Embodiment 9 is the method of any of embodiments 1 to 8, wherein the pyrolysis oil contains more than 10 wt.% unsaturated molecules.
- Embodiment 10 is the method of any of embodiments 1 to 9, wherein the polymer composite tubes are configured to mitigate fouling of unsaturated molecules in the steam cracker.
- Embodiment 11 is the method of any of embodiments 1 to 10, wherein the convection section of the steam cracker includes a feed pre-heater bank, an upper mixed pre-heater bank, and a lower mixed pre-heater bank.
- Embodiment 12 is a method of processing a pyrolysis oil stream.
- the method includes removing heteroatom contaminants from the pyrolysis oil stream in a purification unit to produce a purified pyrolysis oil.
- the method further includes steam-cracking the purified pyrolysis oil stream in a steam cracker to produce olefins and aromatics, wherein the steam cracker includes a feed preheater that includes one or more polymer composite tubes.
Abstract
Description
Claims
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US18/258,678 US20240034943A1 (en) | 2020-12-21 | 2021-11-24 | Systems and methods for steam cracking hydrocarbons |
KR1020237025053A KR20230147051A (en) | 2020-12-21 | 2021-11-24 | Systems and methods for steam cracking hydrocarbons |
EP21819223.5A EP4263760A1 (en) | 2020-12-21 | 2021-11-24 | Systems and methods for steam cracking hydrocarbons |
CN202180092370.0A CN116745389A (en) | 2020-12-21 | 2021-11-24 | System and method for steam cracking hydrocarbons |
JP2023538023A JP2023554684A (en) | 2020-12-21 | 2021-11-24 | System and method for steam cracking hydrocarbons |
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US20190055482A1 (en) * | 2016-02-25 | 2019-02-21 | Sabic Global Technologies, B.V. | An Integrated Process for Increasing Olefin Production by Recycling and Processing Heavy Cracker Residue |
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US20190055482A1 (en) * | 2016-02-25 | 2019-02-21 | Sabic Global Technologies, B.V. | An Integrated Process for Increasing Olefin Production by Recycling and Processing Heavy Cracker Residue |
Non-Patent Citations (1)
Title |
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KAZI S N ET AL: "Mineral scale formation and mitigation on metals and a polymeric heat exchanger surface", APPLIED THERMAL ENGINEERING, PERGAMON, OXFORD, GB, vol. 30, no. 14-15, 1 October 2010 (2010-10-01), pages 2236 - 2242, XP027145596, ISSN: 1359-4311, [retrieved on 20100611] * |
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JP2023554684A (en) | 2023-12-28 |
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