Thermal/catalytic cracking of hydrocarbons for the production of olefins: A state-of-the-art review I: Thermal cracking review (original) (raw)
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A Review on the Production of Light Olefins Using Steam Cracking of Hydrocarbons
Energies
Light olefins are the main building blocks used in the petrochemical and chemical industries for the production of different components such as polymers, synthetic fibers, rubbers, and plastic materials. Currently, steam cracking of hydrocarbons is the main technology for the production of light olefins. In steam cracking, the pyrolysis of feedstocks occurs in the cracking furnace, where hydrocarbon feed and steam are first mixed and preheated in the convection section and then enter the furnace radiation section to crack to the desired products. This paper summarizes olefin production via the steam cracking process; and the reaction mechanism and cracking furnace are also discussed. The effect of different operating parameters, including temperature, residence time, feedstock composition, and the steam-to-hydrocarbon ratio, are also reviewed.
Industrial & Engineering Chemistry Research, 2020
Olens production plants are large-scale processes in most of which gaseous and 2 liquid hydrocarbons are cracked to produce light olens. The complex and large-scale 3 nature of these plants makes it an utmost necessity to design and operate them by using 4 of computer-aided optimization and control methods. This review paper provides an 5 overview of the reported research works on the optimization and control of dierent 6 parts of olen plants. The main research studies are discussed in to main sections of 7 Optimal design, and Process operation and control. In the optimal design section, the 8 state of the optimal design of cracking furnace systems, cold-end separation systems, 9 and separation columns have been studied. Then in process operation and control 10 section, the control of cracking furnaces, the control of cold-end separation systems, 11 real-time optimization of olen plants, cyclic scheduling of cracking furnace systems, 12 production planning of olen plants, and nally, start-up and shutdown operations in 13 these plants have been extensively reviewed. This paper continuous the three review 14 1
Thermal and catalytic cracking of whole crude oils at high severity
Journal of Analytical and Applied Pyrolysis, 2020
The catalytic and thermal cracking of three types of whole crude oils, having API gravity at 34°(AL), 39°(AXL) and 51°(ASL), were investigated via a fixed-bed micro-activity test (MAT) unit at high temperature between 600 and 650°C. Equilibrium FCC catalyst (E-Cat)/ZSM-5 additive was used for catalytic cracking tests at 30 s and catalyst/oil (C/O) ratio of 2.0-6.0. For both thermal and catalytic cracking of all crude oils, the increase in reaction temperature resulted in higher conversion and enhanced yields of C 2-C 4 light olefins, LPG, coke, and dry gas at the expense of naphtha, heavy cycle oil (HCO), and light cycle oil (LCO). In thermal cracking, the yields of C 2-C 4 olefins at 650°C were as follows: AL (22.8 wt.%) > AXL (19.0 wt.%) > ASL (18.8 wt.%) associated with naphtha yields of 34.4, 38.1 and 48.0 wt.%, respectively. Compared with thermal, catalytic cracking over E-Cat/ ZSM-5 enhanced conversion, doubled the yields of light olefins and showed an increase in aromatics content of naphtha fraction. Contrary to thermal cracking, the yields of C 2-C 4 olefins in catalytic cracking were as follows: ASL (42.9 wt.%) > AXL (41 wt.%) > AL (39.1 wt.%) associated with naphtha yields of 31.7, 27.5, and 23.0 wt. %, respectively.
Energy, 2006
Steam cracking for the production of light olefins, such as ethylene and propylene, is the single most energyconsuming process in the chemical industry. This paper reviews conventional steam cracking and innovative olefin technologies in terms of energy efficiency. It is found that the pyrolysis section of a naphtha steam cracker alone consumes approximately 65% of the total process energy and approximately 75% of the total exergy loss. A family portrait of olefin technologies by feedstocks is drawn to search for alternatives. An overview of state-of-the-art naphtha cracking technologies shows that approximately 20% savings on the current average process energy use are possible. Advanced naphtha cracking technologies in the pyrolysis section, such as advanced coil and furnace materials, could together lead to up to approximately 20% savings on the process energy use by state-of-the-art technologies. Improvements in the compression and separation sections could together lead to up to approximately 15% savings. Alternative processes, i.e. catalytic olefin technologies, can save up to approximately 20%. q
2007
Light olefins such as ethylene and propylene, are considered the backbone of the petrochemical industry. They are the precursors of numerous plastic materials, synthetic fibers and rubbers. Commercially proven light olefin production technologies such as Steam Cracking (SC), Fluid Catalytic Cracking (FCC), and Deep Catalytic Cracking (DCC) are believed to have reached their full potential and cannot accommodate current demands of the petrochemical industry. The market demand for ethylene and propylene is projected to be about 140 and 90 million tons by year 2010, respectively. These current technologies cannot respond sufficiently to the rapidly growing demand for propylene, since propylene is only produced as a co-product of ethylene production. In addition, the high-energy consumption and the high GHG emissions are major setbacks for SC, which is regarded as the main light olefin technology. Thus, it is imperative that a new alternative should be developed in order to improve the ...
Presentation of Reactor Types for Thermo-Catalytic Thermal Cracking
The publications of the MultiScience - XXXI. MicroCAD International Scientific Conference, 2017
Thermo-catalytic thermal cracking processes refer to processes of the chemical industry whose input raw material are solid, liquid or gas state hydrocarbons. The purpose of technology is to produce a liquid and gas state hydrocarbon fraction with higher value. As a starting point in our research, we examined thermal cracking of solid and/or rubber waste by means of a fixed and fluid-bed (semi-batch) complex reactor system using a catalyst at 450 °C. Common features of these operations of the chemical industry are the inertised atmosphere, temperatures between 400 and 450 °C and a pressure range close to the atmosphere. However, the selected reactor design may imply a considerable difference as it largely determines the distribution and quality parameters of the valuable products formed. Our publication discusses the optimisation possibilities of reactor constructions of diverse types based on the values measured with the equipment constructed by us and experiences.
Modeling and Simulation for Olefin Production in
2010
— The Ethylene production process is one of the most important aspects of a petrochemical plant. The bulk of the worldwide annual commercial production of Ethylene is based on thermal cracking of petroleum hydrocarbons with steam. This process is commonly called Steam cracking process. This article deals with Amir Kabir Petrochemical Olefin Furnaces that are located in special region of Bandar Imam in Iran and all required information and data for modeling are offered in this article. In this research, the effect of COT (Coil outlet temperature) on the reactor yield is gained. A simulator is developed by the use of a mathematical model, which describes the static operation of a naphtha thermal cracking furnace. The model is used to predict the steady state profile of Ethylene and Propylene products yield. To study even more, the thermal cracking is simulated with Linde company software. The results of mathematical model and simulation have been compared with laboratory results of Ol...
Production of olefins via steam cracking of vegetable oils
Resources, Conservation and Recycling, 2012
Vegetable oils (in Europe particularly rapeseed) are the favoured raw material for production of methyl esters to be used as biodiesel. This paper discloses a possibility of their alternative utilization as crude oil substitute via vegetable oil steam cracking to produce short alkenes to be used in polyolefins production industry. During thermal decomposition under conditions matching those of gas-oil steam cracking (short residence time, temperature over 800 • C) vegetable oils form similar products as traditional crude-oilbased feedstocks. The yields of major pyrolysis products of various vegetable oils were determined using the apparatus employed previously to laboratory research of hydrocarbon pyrolysis and they were compared to yields obtained by cracking traditional feedstocks. Also the effects of hydrocarbon chain length and saturation of acyls forming the oils were analyzed in detail. The possibilities of processing vegetable oils by co-cracking in mixture with crude oil feedstocks are discussed and supported by experimental data.
The Numerical Simulation of Olefin Production Furnace for Pollution Reduction: Two case studies
2021
One of the most important petrochemical processes is olefin production, and the most important part of this process is the thermal cracking furnace. The analysis of the flow and combustion process in these furnaces is important. In this research, combustion analysis in these furnaces has been investigated by examining two case studies of thermal cracking furnaces. The governing equations of the problem process, including mass and momentum and energy equations, along with combustion equations, are solved in CFX software. Temperature profiles are obtained at different points. The heat flux is obtained at different heights of the furnace. The hot spots obtained on the reactor as well as the simulation of the conversion of raw materials into products during the reactor are based on the simulation of the furnace by placing burners on the floor of the furnace (Ilam Petrochemical Olefin).Then, for the second case study, including the placement of burners in the floor and wall of the furna...
Mathematical Modeling of Ethane Cracking Furnace of Olefin Plant with Coke Formation Approach.pdf
International Journal of Chemical Reactor Engineering. 2018; 20170243, 2018
in this study, ethylene furnace modeling is carried out by ethane pyrolysis (thermal cracking or hydrocracking) method in Arya Sasol Petrochemical Company (ninth olefin unit, Assaluyeh, Iran), which includes the solution of kinetic equations and transfer phenomena, by the forward finite difference method in the MATLAB. Due to study and compare coke formation, a specific time period has been selected in equal segments and equations have been solved. It means that in a length segment of coil (Δz), momentum, energy as well as mass equations are solved, then the amount of precipitated coke in each length segment is achieved. With new efficient coil diameter calculating all mentioned approach will be repeated for next time segment. The results of this model have been compared with actual data and deviation has been reported. It was found that modeling approach is more capable to define the parameters of coke formation equations. The model has a good agreement between the values of prediction and experimental of in most cases.