Process for improving propylene recovery from FCC recovery unit

Abstract

The present subject matter relates generally to processes for propylene recovery. More specifically, the present subject matter relates to processes for enhanced recovery of propylene and liquid petroleum gas (LPG) from the fuel gas produced in fluid catalytic cracking (FCC) units by minimizing the light ends and propylene in the unstabilized gasoline which is used as lean oil for the primary absorber of the FCC gas concentration unit.

Claims

1. A process for the recovery of propylene comprising: (i) contacting a hydrocarbon feed with a catalyst in a fluid catalytic cracking process to produce a product stream; (ii) distilling the product stream in a fractionator to obtain heavier liquid products as side/bottom draws and a gaseous top product; (iii) cooling and condensing the gaseous top product and thereafter, separating the obtained gas-liquid mixture in a receiver to obtain a liquid fraction and a lighter gaseous fraction; (iv) sequentially sending the gaseous fraction obtained from step (iii) to a wet gas compressor train; (v) feeding a first portion of the liquid fraction obtained in step (iii) back to the fractionator; (vi) feeding a second portion of the liquid fraction obtained in step (iii) to at least one heat exchanger to produce a heated stream; and (vii) feeding the heated stream to a flash drum to produce a flashed light ends stream to be sent back to the wet gas compressor in step (iv) and a bottoms liquid stream wherein the bottoms stream is sent to one or more heat exchangers in step (vi) before routing the liquid stream to FCC gas concentration absorber.

2. The process of claim 1 wherein the one or more heat exchangers heats the liquid fraction from about 38 C. to about 80 C.

3. The process of claim 1 wherein the flashed light ends stream contains nearly 70% of the propylene in the flash drum feed.

4. The process of claim 1 wherein one or more of the heat exchanges uses a waste heat process stream.

5. The process of claim 1 wherein two heat exchangers are used to heat the liquid fraction.

6. A process for the recovery of propylene comprising: (i) contacting a hydrocarbon feed with a catalyst in a fluid catalytic cracking process to produce a product stream; (ii) distilling the product stream in a fractionator to obtain heavier liquid products as side/bottom draws and a gaseous top product; (iii) cooling and condensing the gaseous top product and thereafter, separating the obtained gas-liquid mixture in a receiver to obtain a liquid fraction and a lighter gaseous fraction; (iv) sequentially sending the gaseous fraction obtained from step (iii) to a wet gas compressor; (v) feeding a first portion of the liquid fraction obtained in step (iii) back to the fractionator; (vi) feeding a second portion of the liquid fraction obtained in step (iii) to at least one heat exchanger to produce a heated stream; and (vii) feeding the heated stream to a split shell flash drum having a first side and a second side wherein the heated stream is sent to the first side of the split shell to produce a first flashed light ends stream to be sent back to the wet gas compressor in step (iv) and a first bottoms stream wherein the bottoms stream is heated and sent to the second side of the split shell flash drum to produce a second flashed light ends stream to be sent back to the wet gas compressor in step (iv) and a second bottoms stream wherein the second bottoms stream is sent to one or more heat exchangers in step (vi) before routing liquid stream to FCC gas concentration absorber.

7. The process of claim 6 wherein the one or more heat exchangers heats the liquid fraction from about 38 C. to about 80 C.

8. The process of claim 6 wherein the flashed light ends stream contains nearly 70% of the propylene in the flash drum feed.

9. The process of claim 6 wherein one or more of the heat exchanges uses a waste heat process stream.

10. The process of claim 6 wherein two heat exchangers are used to heat the liquid fraction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.

(2) FIG. 1 illustrates the prior art process.

(3) FIG. 2 is an illustration of the overall flow scheme of the system for improving propylene recovery from FCC gas using a flash drum for unstabilized gasoline before routing it to the primary absorber of gas concentration unit.

(4) FIG. 3 is an illustration of the overall flow scheme of the system for improving propylene recovery from FCC gas using a split shell flash drum for unstabilized gasoline before routing it to the primary absorber of gas concentration unit.

DETAILED DESCRIPTION

(5) The following detailed description is merely exemplary in nature and is not intended to limit the application and uses of the embodiment described. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

(6) FIG. 1 illustrates a diagram of various embodiments of the processes described herein. Those skilled in the art will recognize that this process flow diagram has been simplified by the elimination of many pieces of process equipment including for example, heat exchangers, process control systems, pumps, fractionation column overhead, reboiler systems and reactor internals, etc. which are not necessary to an understanding of the process. It may also be readily discerned that the process flow presented in the drawing may be modified in many aspects without departing from the basic overall concept. For example, the depiction of required heat exchangers in the drawing has been held to a minimum for purposes of simplicity. Those skilled in the art will recognize that the choice of heat exchange methods employed to obtain the necessary heating and cooling at various points within the process is subject to a large amount of variation as to how it is performed. In a process as complex as this, there exists many possibilities for indirect heat exchange between different process streams. Depending on the specific location and circumstance of the installation of the subject process, it may also be desired to employ heat exchange against steam, hot oil, or process streams from other processing units not shown on the drawing.

(7) Existing process for recovering gaseous products from the product mixture obtained by contacting a hydrocarbon feed with a catalyst in a fluid catalytic cracking process is shown in FIG. 1. Gaseous mixture from top of main fractionator 12 is supplied to overhead cooler-condenser 16 via gas conduit 14. Gas-liquid fractions thus obtained are separated in overhead receiver drum separator 24. The separated liquid fraction referred to as unstabilized naphtha is supplied as lean oil to primary absorber 75 via liquid conduit 27. The gaseous fraction is supplied via conduit 26 to suction of the first stage compressor 76. The discharge stream via conduit 77 after getting cooled in inter-stage cooler 78 being separated into gas and liquid fractions in inter-stage drum 80. The gas fraction from inter-stage drum 80 is supplied via conduit 81 to second stage compressor 84. The inter-stage liquid fraction from inter-stage drum 80 via conduit 82 is combined in conduit 85 with the gaseous fraction compressed in second stage 84. The combined stream in conduit 85 is further joined by rich oil stream liquid from primary absorber 75 via conduit 94 and the overhead gaseous fraction from stripper 92 via conduit 93. The resultant stream 87 after it is cooled in high pressure cooler 86 is separated into gas and liquid fractions in high pressure receiver separator 89.

(8) The liquid fraction obtained from separator 89 is fed via conduit 91 to a stripper 92 wherein components lighter than ethane are stripped off from the feed and are recycled back via conduit 93 to high pressure separator 89. Bottoms of stripper 92 are fed via conduit 95 to a debutanizer column 96 where components lighter than butane present in the feed are separated as column overheads and are fed further to a propylene separation unit via conduit 97. Bottom of debutanizer 96 in conduit 97 after being cooled in exchanger 98 to about 38 C. to about 40 C. is split to gasoline recycle and supplied to primary absorber 75 via conduit 100.

(9) Gaseous fraction from the high pressure separator 89, comprising of lighters and C.sub.3-C.sub.5 components, is fed via conduit 90 to the bottom of primary absorber 75 wherein C.sub.3-C.sub.5 components are absorbed by the down-flowing lean absorber oil. The gaseous fraction obtained from primary absorber 75 is fed via conduit 101 to sponge absorber 102. Using light cycle oil as lean oil via conduit 104 in sponge absorber 102, the resulted gas fraction in conduit 103 from sponge absorber 102 contains light gases of C.sub.2 and lighter and some losses of C.sub.3. The absorbed hydrocarbons in sponge absorber 102 are recycled back to main fractionators via conduit 105.

(10) As explained above, the existing process for recovering gaseous products from the product mixture obtained by contacting a hydrocarbon feed with a catalyst in a fluid catalytic cracking process uses unstabilized gasoline from main fractionator overhead receiver as lean oil to gas concentration primary absorber. However, by heating up the unstabilized gasoline and flashing the lighter ends and the propylene before routing to primary absorber will increase the total propylene recovery in the gas concentration unit. This design not only improves the recovery of propylene, but it is more economical to use a flash drum as opposed to other traditional methods used in gas concentration units and mainly gasoline recycle from the debutanizer which increases equipment sizes and utilities. This design will increase the load on the wet gas compressor by about 2% to about 5% but it is much more economical than increasing the gasoline recycle in gas concentration unit. For new units design the increase in propylene recovery becomes uneconomical using traditional methods at certain level.

(11) For existing units the investment to increase propylene recovery will be too large and requires many equipment modifications. With this invention and for new units design propylene recovery near 99.6% are economically possible. For existing units, propylene recovery can be increased by nearly 1% without modifications for existing equipment. The extra load on the existing wet compressor of about 2% to about 5% can be accommodated by slightly changing the suction operating pressure if the compressor is near its maximum limit. For existing FCC units, the new equipment can be designed and installed in typical turnaround or in some cases may be while the unit is in operation. In addition for existing units with equipment limitations of stripper, debutanizer, stripper reboiler, debutanizer reboiler and debutanizer overhead condenser, it will be possible to reduce the gasoline recycle and maintain same C.sub.3 recovery. This will allow more feed to the gas concentration unit or more propylene production at FCC reactor.

(12) As illustrated in the preferred embodiment in FIG. 2, a process 100 for the recovery of propylene is depicted. In this embodiment, a gaseous mixture in conduit 14 from the top of main fractionator 12 is supplied to an overhead air cooler 16 and is then supplied to a cooler-condenser 20 via gas/liquid conduit 18. Gas-liquid fractions thus obtained are separated in a overhead receiver 24. The separated liquid fraction unstabilized gasoline leaves the receiver 24 via liquid conduit 28 while the gas leaves the receiver via conduit 26 to wet gas compressor. The unstabilized gasoline via conduit 28 is split and a portion of the liquid fraction in conduit 29 is sent back to the main fractionator 12. The net unstabilized gasoline liquid fraction in conduit 27 is then heated via feed/bottoms exchanger 30. The resultant stream in conduit 38 obtained from heat exchanger 30 is fed to heat exchanger 40 for further heating by a stream in conduit 42. The stream of conduit 42 can either be a process stream or LP steam. Liquid gas mixture from heat exchanger 40 is fed via conduit 44 to a flash drum 46.

(13) The gaseous fraction in conduit 48 obtained from flash drum 46 is supplied to conduit 26 before the wet gas compressor. The flash drum vapor in conduit 48 contain light ends and nearly 70% of the propylene in the flash drum feed from conduit 44. The flash drum liquid in conduit 50 is pumped to feed/bottoms exchanger 30, cooled in a water cooler 34 to about 35 C. to about 40 C. and then routed to primary absorber. Therefore, the liquid to the primary absorber has less light material and propylene and therefore less loading on primary absorber which results in higher propylene recovery for the gas concentration unit.

(14) As illustrated in another preferred embodiment in FIG. 3, a process 200 for the recovery of propylene is depicted. In this process a two stage flash for unstabilized gasoline is used before routing to gas concentration unit primary absorber. In this embodiment, a gaseous mixture in conduit 14 from the top of main fractionator 12 is supplied to an overhead air cooler 16 and is then supplied to a cooler-condenser 20 via gas/liquid conduit 18. Gas-liquid fractions thus obtained are separated in a overhead receiver 24. The separated liquid fraction unstabilized gasoline leaves the receiver 24 via liquid conduit 28 while the gas leaves the receiver via conduit 26 to wet gas compressor. The unstabilized gasoline via conduit 28 is split and a portion of the liquid fraction in conduit 29 is sent back to the main fractionator 12. The net unstabilized gasoline liquid fraction in conduit 27 is then heated via feed/bottoms exchanger 30. The resultant stream in conduit 38 obtained from heat exchanger 30 is fed to a split shell flash drum 60. The flash drum illustrated in FIG. 2 comprises a split shell flash drum having a first side 70 and a second side 72 wherein the first side 70 and the second side 72 are completely separated by a vertical wall and the contents of the first side and the second side do not come in contact with each other. The gaseous fraction in conduit 48 obtained from flash drum 60 and side 70 is supplied to conduit 26 before the wet gas compressor.

(15) The first bottom stream 44 from the first side 70 of the split shell flash drum 60 is pumped via conduit 44 to heat exchanger 40 for further heating by a stream in conduit 42. The stream of conduit 42 can either be a process stream or LP steam. The resultant stream from exchanger 40 leaves via conduit 51 and send to the second side 72 of the split shell flash drum 60. The second overhead stream 58 from the second side 72 of the split shell flash drum 60 is supplied to conduit 26 before the wet gas compressor. The second bottoms stream 50 from the second side 72 of the split shell flash drum 60 is pumped to feed/bottoms exchanger 30, cooled in a water cooler 34 to about 35 C. to 40 C. and then routed to primary absorber. Therefore, the liquid to the primary absorber has less light material and propylene and therefore less loading on primary absorber which results in higher propylene recovery for the gas concentration unit.

EXAMPLES

(16) The following examples are intended to further illustrate the subject embodiments. These illustrations of different embodiments are not meant to limit the claims to the particular details of these examples.

Example 1

(17) An FCC unit was designed as per the prior art flow scheme. It was possible to achieve propylene recovery of 98.93 mol %. Any additional propylene recovery using traditional methods was not possible and was not economical. By adding the new invention to the design of the unit, it was possible to achieve higher recovery which resulted in higher revenue and payback of a few months based on new equipment cost. A comparison of base case vs. the case with the additional of new equipments is shown in Table 1.

(18) TABLE-US-00001 TABLE 1 New case: Base Case with the addi- Base tion of new Delta Case equipment New vs. Base Propylene Recovery, % 98.93 99.61 0.68 Propylene Recovered, 735848.1 740848.3 5000.2 Metric T/year Propane Recovered, 118510.8 119091.5 580.7 Metric T/year Value of delta 5.86 Propylene & propane recovered, MM$/year Loss of value of 1.21 Propylene & propane in Fuel Gas MM$/year Operating Cost using 1.5 LP steam, MM$/year Net Revenue, MM$/year 3.15 Equipment Cost, MM$ 0.86 Payback based on 3 to 4 equipment cost, Months

(19) As shown in the above Table 1, with new invention it was possible to achieve higher propylene recovery and the payback for the new equipment investment is expected to be a few months. In addition, the above analysis was done for the worst case scenario using LP steam for heating the unstabilized gasoline. In most cases it will be possible to heat up the unstabilized gasoline with a waste heat process stream available in the gas recovery or FCC main fractionation section. This will increase the yearly revenue from MM$3.15 to MM$4.65

(20) Another analysis we performed is the affect of the new invention on gasoline recycle.

(21) For same propylene as the base case of example 1 and with the addition of flash drum, it was possible to reduce gasoline recycle from the debutanizer to absorber by 50%. This has a big saving in equipment sizes and utilities on the gas concentration equipment like primary absorber, stripper, debutanizer, stripper reboiler, debutanizer reboiler/overhead condenser and gas concentration unit water coolers.

Example 2

(22) For existing units and if it is desired to reduce the load on wet gas compressor due to capacity limitations, split shell design can be used for the flash drum as illustrated in FIG. 2. The benefit is a reduction of the vapor to wet gas compressor while maintaining same recovery in gas concentration unit. The amount of propylene removed from the unstabilized gasoline is the same as with a single flash drum but amount of vapor going to wet gas compressor will be less as shown in Table 2 below.

(23) TABLE-US-00002 TABLE 2 Unstabilized gasoline flow, kg/h: 257,508 Flash Drum Flash Drum Flash Drum Flash Drum Vapor Dividing Dividing Dividing wall without Wall Vapor Wall Vapor Total vapor Dividing from 1.sup.st from 2.sup.nd from 1.sup.st & 2.sup.nd Wall Compartment Compartment Compartments Vapor Flow, kg/h 25671 3925 18404 22329 Vapor Flow as % of 4.77 0.73 3.42 4.15 Wet Gas Compressor Normal flow Temperature, C. 79 60 79 76 Propylene In vapor, 1794 567 1234 1801 kg/h Wet Gas Compressor 39.7 39.3 suction temperature(normal flow + flash drum vapor), C.

(24) As shown in the above table, the flow to wet gas compressor will be reduced when using a split shell or dividing wall drum for nearly the same amount of propylene removal from unstabilized gasoline. In addition the total flow going to wet gas compressor will be slightly at a lower temperature.

(25) It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present subject matter and without diminishing its attendant advantages.

Specific Embodiments

(26) While the following is described in conjunction with specific embodiments, it will be understood that this description is intended to illustrate and not limit the scope of the preceding description and the appended claims.

(27) A first embodiment of the invention is a process for the recovery of propylene comprising (i) contacting a hydrocarbon feed with a catalyst in a fluid catalytic cracking process to produce a product stream; (ii) distilling the product stream in a fractionator to obtain heavier liquid products as side/bottom draws and a gaseous top product; (iii) cooling and condensing the gaseous top product and thereafter, separating the obtained gas-liquid mixture in a receiver to obtain a liquid fraction and a lighter gaseous fraction; (iv) sequentially sending the gaseous fraction obtained from step (iii) to a wet gas compressor train; (v) feeding a first portion of the liquid fraction obtained in step (iii) back to the fractionator; (vi) feeding a second portion of the liquid fraction obtained in step (iii) to at least one heat exchanger to produce a heated stream; and (vii) feeding the heated stream to a flash drum to produce a flashed light ends stream to be sent back to the wet gas compressor in step (iv) and a bottoms liquid stream wherein the bottoms stream is sent to one or more heat exchangers in step (vi) before routing the liquid stream to FCC gas concentration absorber. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the one or more heat exchangers heats the liquid fraction from about 38 C. to about 80 C. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the flashed light ends stream contains nearly 70% of the propylene in the flash drum feed. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein one or more of the heat exchanges uses a waste heat process stream. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein two heat exchangers are used to heat the liquid fraction.

(28) A second embodiment of the invention is a process for the recovery of propylene comprising (i) contacting a hydrocarbon feed with a catalyst in a fluid catalytic cracking process to produce a product stream; (ii) distilling the product stream in a fractionator to obtain heavier liquid products as side/bottom draws and a gaseous top product; (iii) cooling and condensing the gaseous top product and thereafter, separating the obtained gas-liquid mixture in a receiver to obtain a liquid fraction and a lighter gaseous fraction; (iv) sequentially sending the gaseous fraction obtained from step (iii) to a wet gas compressor; (v) feeding a first portion of the liquid fraction obtained in step (iii) back to the fractionator; (vi) feeding a second portion of the liquid fraction obtained in step (iii) to at least one heat exchanger to produce a heated stream; and (vii) feeding the heated stream to a split shell flash drum having a first side and a second side wherein the heated stream is sent to the first side of the split shell to produce a first flashed light ends stream to be sent back to the wet gas compressor in step (iv) and a first bottoms stream wherein the bottoms stream is heated and sent to the second side of the split shell flash drum to produce a second flashed light ends stream to be sent back to the wet gas compressor in step (iv) and a second bottoms stream wherein the second bottoms stream is sent to one or more heat exchangers in step (vi) before routing liquid stream to FCC gas concentration absorber. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the one or more heat exchangers heats the liquid fraction from about 38 C. to about 80 C. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the flashed light ends stream contains nearly 70% of the propylene in the flash drum feed. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein one or more of the heat exchanges uses a waste heat process stream. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein two heat exchangers are used to heat the liquid fraction.

(29) Without further elaboration, it is believed that using the preceding description that one skilled in the art can utilize the present invention to its fullest extent and easily ascertain the essential characteristics of this invention, without departing from the spirit and scope thereof, to make various changes and modifications of the invention and to adapt it to various usages and conditions. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limiting the remainder of the disclosure in any way whatsoever, and that it is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.

(30) In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.