The technical field generally relates to hydrocarbon processing apparatuses and methods of refining hydrocarbons, and more particularly relates to hydrocarbon processing apparatuses and methods of refining hydrocarbons with absorptive recovery of C3+ hydrocarbons from a high pressure vapor stream.
Fluid catalytic cracking (FCC) is a well-known process for the conversion of relatively high boiling point hydrocarbons to lighter boiling hydrocarbons in the heating oil or gasoline (or lighter) range. Such processes are commonly referred to in the art as “upgrading” processes, and “FCC” as referred to herein encompasses conventional FCC processes and residual FCC processes. To conduct FCC processes, FCC units are generally provided with one or more reaction chambers. A hydrocarbon stream is typically contacted in the one or more reaction chambers with a particulate cracking catalyst that is maintained in a fluidized state under conditions that are suitable for the conversion of relatively high boiling point hydrocarbons to lighter boiling hydrocarbons.
Typically, the lighter boiling hydrocarbons are withdrawn from the FCC unit as an offgas stream, which is separated into various intermediate and product hydrocarbon streams in an FCC main column. A fraction that remains in vapor form from the FCC main column is taken as a main column overhead stream and fed to an overhead receiver, where liquid fractions and a residual vapor stream are separated. The residual vapor stream is compressed to form a pressurized stream in preparation for further separation of components therefrom. In particular, the pressurized stream is generally fed to a high pressure receiver, which separates the pressurized stream into one or more liquid streams and a high pressure vapor stream. It is generally desirable to separate C3+ hydrocarbons from the high pressure vapor stream, and such separation is often conducted through liquid-vapor phase absorption in a primary absorber. As referred to herein, “CX” means hydrocarbon molecules that have “X” number of carbon atoms, CX+ means hydrocarbon molecules that have “X” and/or more than “X” number of carbon atoms, and CX− means hydrocarbon molecules that have “X” and/or fewer than “X” number of carbon atoms.
To separate C3+ hydrocarbons from the high pressure vapor stream, a stabilized and/or unstabilized gasoline stream is often employed as a liquid absorption stream in the primary absorber. The stabilized gasoline stream is generally derived from the high pressure vapor stream and may be provided from a debutanizer column after separation of C4− hydrocarbons. The unstabilized gasoline stream contains C4+ hydrocarbons and is generally derived from the main column overhead stream as a liquid stream provided from the overhead receiver. A high flow rate of the stabilized and/or unstabilized gasoline streams is often required to effectively separate the C3+ hydrocarbons in the primary absorber, which impacts capital and operating expenses associated with separation of C3+ hydrocarbons from the high pressure vapor stream.
Accordingly, it is desirable to provide hydrocarbon processing apparatuses and methods of refining hydrocarbons with minimized flow rate of stabilized and/or unstabilized gasoline streams during absorptive separation of C3+ hydrocarbons from the high pressure vapor stream. Furthermore, other desirable features and characteristics will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background.
Hydrocarbon processing apparatuses and methods of refining hydrocarbons are provided herein. In an embodiment, a method of refining hydrocarbons includes providing a cracked stream that includes a sulfur-containing component and cracked hydrocarbons. The cracked stream is compressed to produce a pressurized cracked stream. The pressurized cracked stream is separated to produce a pressurized vapor stream and a liquid hydrocarbon stream. The pressurized vapor stream includes C4− hydrocarbons and the liquid hydrocarbon stream includes C3+ hydrocarbons. The liquid hydrocarbon stream is separated to produce a first liquid absorption stream that includes C5+ hydrocarbons and a C4− hydrocarbon stream. C3+ hydrocarbons are absorbed from the pressurized vapor stream through liquid-vapor phase absorption using the first liquid absorption stream. The sulfur-containing component is removed prior to absorbing C3+ hydrocarbons from the pressurized vapor stream.
In another embodiment, a method of refining hydrocarbons includes cracking a hydrocarbon stream that includes a sulfur-containing component in a fluid catalytic cracking stage to produce a cracked stream that includes the sulfur-containing component and cracked hydrocarbons. The cracked stream is compressed to produce a pressurized cracked stream. The pressurized cracked stream is separated in a pressurized separation stage to produce a pressurized vapor stream and a liquid hydrocarbon stream. The pressurized vapor stream includes C4− hydrocarbons and the liquid hydrocarbon stream includes C3+ hydrocarbons and the sulfur-containing component. The liquid hydrocarbon stream is fractionated to produce an intermediate C3+ stream and a recovered C3− vapor stream. The C3+ stream includes C3+ hydrocarbons and the recovered C3− vapor stream includes C3− hydrocarbons and the sulfur-containing component. The sulfur-containing component is removed from the recovered C3− vapor stream to produce a purified C3− vapor stream. The purified C3− vapor stream is recycled to the pressurized separation stage. C3+ hydrocarbons from the pressurized vapor stream are absorbed through liquid-vapor phase absorption using a liquid absorption stream.
In another embodiment, a hydrocarbon processing apparatus includes a fluid catalytic cracking unit that has the capacity to catalytically crack a hydrocarbon stream that includes a sulfur-containing component, and the fluid catalytic cracking unit further has the capacity to produce an offgas stream that includes the sulfur-containing component and cracked hydrocarbons. A compressor is in fluid communication with the fluid catalytic cracking unit and has the capacity to produce a pressurized cracked stream. A high pressure receiver is in fluid communication with the compressor and has the capacity to separate the pressurized cracked stream into a pressurized vapor stream and a liquid hydrocarbon stream. A debutanizer column is in fluid communication with the high pressure receiver and has the capacity to produce a first liquid absorption stream. A liquid-vapor phase separator is in fluid communication with the debutanizer column. The liquid-vapor phase separator is configured to contact the pressurized vapor stream and the first liquid absorption stream therein. A contaminant removal unit is disposed upstream of the liquid-vapor phase separator and downstream of the fluid catalytic cracking unit. The contaminant removal unit is configured to remove the sulfur-containing component.
The various embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
The following detailed description is merely exemplary in nature and is not intended to limit the hydrocarbon processing apparatuses or methods of refining hydrocarbons. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
Hydrocarbon processing apparatuses and methods of refining hydrocarbons are provided herein that enable efficient recovery of C3+ hydrocarbons from a high pressure vapor stream obtained from fluid catalytic cracking. In particular, without being bound by theory, it is believed that the presence of a sulfur-containing component in the high pressure vapor stream inhibits C3+ absorption using a stabilized and/or unstabilized gasoline stream and, thus, necessitates higher flow rates of the stabilized and/or unstabilized gasoline streams during absorptive separation of C3+ hydrocarbons from the high pressure vapor stream than may otherwise be required to effectively separate the C3+ hydrocarbons. Many hydrocarbon feedstocks that are subject to FCC processing include sulfur-containing species, and the sulfur-containing species remain in the resulting cracked stream that is produced by FCC processing. As referred to herein, the “sulfur-containing component” includes all sulfur-containing species that may be present in the cracked stream that is produced during FCC processing. An example of a common sulfur-containing species that may be included in the cracked stream is hydrogen sulfide. In accordance with the methods and apparatuses described herein, the sulfur-containing component is removed prior to absorbing C3+ hydrocarbons from the pressurized vapor stream, thereby maximizing C3+ recovery efficiency during absorptive separation of the C3+ hydrocarbons from the high pressure vapor stream. By “prior to” or “upstream” as referred to herein, it is meant that the sulfur-containing component may be removed from the high pressure vapor stream or from any stream that contains components that are eventually included in the high pressure vapor stream. For example, the sulfur-containing component may be removed from the high pressure vapor stream or from a recovered C3− vapor stream that is recycled and that includes C3 hydrocarbons that are eventually included in the high pressure vapor stream. Additionally, it is to be appreciated that removal of the sulfur-containing component refers to partial or complete removal of the sulfur-containing component from the referenced stream.
An embodiment of a method of refining hydrocarbons will now be described with reference to an exemplary hydrocarbon processing apparatus 10 as shown in
The cracked stream 12 is compressed to produce a pressurized cracked stream 28, and the pressurized cracked stream 28 is separated in a pressurized separation stage to produce a pressurized vapor stream 36 that includes C4− hydrocarbons and a liquid hydrocarbon stream 38 that includes C3+ hydrocarbons. In an embodiment and referring again to
The liquid hydrocarbon stream 38 is separated to produce a first liquid absorption stream 48 that includes C5+ hydrocarbons and a C4− hydrocarbon stream 50. As referred to herein, the first liquid absorption stream 48 is a stream that is employed for absorptive separation of C4− hydrocarbons from pressurized vapor stream 36, as described in further detail below. As alluded to above, some C3− hydrocarbons may remain in the liquid hydrocarbon stream 38 due to limits of liquid/vapor phase separation in the high pressure receiver 34. It is to be appreciated that intermediate unit operations may be conducted to separate C3− hydrocarbons from the liquid hydrocarbon stream 38 prior to separating the first liquid absorption stream 48 therefrom. For example, C3− hydrocarbons may be fractionated from the liquid hydrocarbon stream 38 to produce a recovered C3− vapor stream 54 and an intermediate C3+ stream 56. In particular, in an embodiment and as shown in
In accordance with an embodiment, the sulfur-containing component is removed from the pressurized vapor stream 36 to produce a sulfur-containing waste stream 44 and a purified pressurized vapor stream 46. In this embodiment, at least some of the sulfur-containing component is separated with the pressurized vapor stream 36 during separation of the pressurized cracked stream 28 into the pressurized vapor stream 36 and the liquid hydrocarbon stream 38. It is to be appreciated that, in accordance with the methods described herein, at least a portion of the sulfur-containing component is removed; the entire sulfur-containing component need not be separated so long as at least some of the sulfur-containing component is separated. However, in embodiments, at least about 95 weight % of the sulfur-containing component is removed, such as at least about 99 weight %, based upon an original amount of the sulfur-containing component in the stream from which the sulfur-containing component is removed. In an embodiment and as shown in
In accordance with the exemplary method, C3+ hydrocarbons are absorbed from the pressurized vapor stream 36 through liquid-vapor phase absorption using a liquid absorption stream. In an embodiment and as shown in
Absorbing the C3+ hydrocarbons from the purified pressurized vapor stream 46 generally produces a residual vapor stream 62 that includes residual C3− hydrocarbons, and possibly small amounts of C4 hydrocarbons, due to separation limits during conventional operation of liquid-vapor phase absorption. In embodiments, most of the residual C3 and C4 hydrocarbons are absorbed from the residual vapor stream 62 using a third liquid absorption stream 64 that is different from the first liquid absorption stream 48. For example, a light cycle oil stream 64 may be employed as the third liquid absorption stream 64, and the light cycle oil stream 64 may be produced as a fraction taken from the offgas stream 18 by the FCC main column 20. In an embodiment and as shown in
Another embodiment of a method of refining hydrocarbons will now be described with reference to an exemplary hydrocarbon processing apparatus 210 as shown in
While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims.
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Number | Date | Country | |
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20160130512 A1 | May 2016 | US |