Targeted Catalytic Cracking to Olefins(TCO):Reaction Mechanism,Production Scheme,and Process Perspectives

Light olefins are important organic building blocks in the chemicals industry.The main low-carbon olefin production methods,such as catalytic cracking and steam cracking,have considerable room for improvement in their utilization of hydrocarbons.This review provides a thorough overview of recent studies on catalytic cracking,steam cracking,and the conversion of crude oil processes.To maximize the production of light olefins and reduce carbon emissions,the perceived benefits of various technologies are examined.Taking olefin generation and conversion as a link to expand upstream and downstream processes,a targeted catalytic cracking to olefins(TCO)process is proposed to meet current demands for the transformation of oil refining into chemical production.The main innovations of this process include a multiple feedstock supply,the development of medium-sized catalysts,and a diameter-transformed fluidizedbed reactor with different feeding schemes.In combination with other chemical processes,TCO is expected to play a critical role in enabling petroleum refining and chemical processes to achieve low carbon dioxide emissions.

Data-driven intelligent modeling framework for the steam cracking process

Steam cracking is the dominant technology for producing light olefins,which are believed to be the foundation of the chemical industry.Predictive models of the cracking process can boost production efficiency and profit margin.Rapid advancements in machine learning research have recently enabled data-driven solutions to usher in a new era of process modeling.Meanwhile,its practical application to steam cracking is still hindered by the trade-off between prediction accuracy and computational speed.This research presents a framework for data-driven intelligent modeling of the steam cracking process.Industrial data preparation and feature engineering techniques provide computational-ready datasets for the framework,and feedstock similarities are exploited using k-means clustering.We propose LArge-Residuals-Deletion Multivariate Adaptive Regression Spline(LARD-MARS),a modeling approach that explicitly generates output formulas and eliminates potentially outlying instances.The framework is validated further by the presentation of clustering results,the explanation of variable importance,and the testing and comparison of model performance.

Stress corrosion cracking of magnesium alloys:A review

Magnesium(Mg)alloys have been widely used in automobile,aviation,computer,and other fields due to their lightweight,high specific strength and stiffness,low pollution,and good electromagnetic shielding performance.However,the chemical stability of Mg alloys is poor,especially in the corrosive medium environment with high stress corrosion sensitivity,which causes sudden damage to structural components and restricts their application field.In recent years,owing to the increasing failure rate of engineering structures caused by stress corrosion of Mg alloys,it has become necessary to understand and pay more attention to the stress corrosion cracking(SCC)behavior of Mg alloys.In this paper,the SCC mechanisms and test methods of Mg alloys have been summarized.The recent research progress on SCC of Mg alloys has been reviewed from the aspects of alloying,preparation process,surface modification,corrosive medium,and strain rate.More importantly,future research trends in the field of SCC of Mg alloys have also been proposed.

A Novel Close-loop Strategy for Integrating Process Operations of Fluidized Catalytic Cracking Unit with Production Planning Optimization

Production planning models generated by common modeling systems do not involve constraints for process operations, and a solution optimized by these models is called a quasi-optimal plan. The quasi-optimal plan cannot be executed in practice some time for no corresponding operating conditions. In order to determine a practi- cally feasible optimal plan and corresponding operating conditions of fluidized catalytic cracking unit （FCCU）, a novel close-loop integrated strategy, including determination of a quasi-optimal plan, search of operating conditions of FCCU and revision of the production planning model, was proposed in this article. In the strategy, a generalized genetic algorithm （GA） coupled with a sequential process simulator of FCCU was applied to search operating conditions implementing the quasi-optimal plan of FCCU and output the optimal individual in the GA search as a final genetic individual. When no corresponding operating conditions were found, the final genetic individual based correction （FGIC） method was presented to revise the production planning model, and then a new quasi-optimal production plan was determined. The above steps were repeated until a practically feasible optimal plan and corresponding operating conditions of FCCU were obtained. The close-loop integrated strategy was validated by two cases, and it was indicated that the strategy was efficient in determining a practically executed optimal plan and corresponding operating conditions of FCCU.

Modeling and Optimization of Ethane Steam Cracking Process in An Industrial Tubular Reactor with Improved Reaction Scheme

Ethane steam cracking process in an industrial reactor was investigated.An one-demsional(1D)steady-state model was developed firstly by using an improved molecular reaction scheme and was then simulated in Aspen Plus.A comparison of model results with industrial data and previously reported results showed that the model can predict the process kinetics more accurately.In addition,the validated model was used to study the effects of different process variables,including coil outlet temperature(COT),steam-to-ethane ratio and residence time on ethane conversion,ethylene selectivity,products yields,and coking rate.Finally,steady-state optimization was conducted to the operation of industrial reactor.The COT and steam-to-ethane ratio were taken as decision variables to maximize the annual operational profit.

Two-stage treatment process of pickling wastewater in the cold-rolling production of stainless steel

Based on the characteristics of pickling wastewater in the cold-rolling production of stainless steel, a new processing route, featuring source sludge reduction, wastewater two-stage treatment, heavy metal-contained sludge and calcium salt sludge separating recovery, was proposed. As shown by the research results, after the two-stage process treatment, the effluent water can steadily reach the emission standards, the sludge yield can be decreased by more than 8% ; within the heavy metal-contained sludge, the recovery rates of Fc,Cr and Ni can either reach or surpass 95% ,and the total content ofF and S can drop to around 3%. Therefore,the sludge in the front part can be used as ferric dust. In the calcium salt sludge ,the recovery rate of F can either reach or surpass 85% ,and the total contents of Fe,Cr and Ni can fall below 0.5%. So the sludge in the rear part can be used as fluorgypsum or fluorite. Meanwhile,the results of the analysis on heavy metals leaching toxicity and morphologic distribution indicate that the two kinds of sectionalized sludge are not classified as hazardous wastes, which have a stable behavior and better utilization values compared with the former mixed- sludge.

Peri-Net-Pro: the neural processes with quantified uncertainty for crack patterns

This paper develops a deep learning tool based on neural processes(NPs)called the Peri-Net-Pro,to predict the crack patterns in a moving disk and classifies them according to the classification modes with quantified uncertainties.In particular,image classification and regression studies are conducted by means of convolutional neural networks(CNNs)and NPs.First,the amount and quality of the data are enhanced by using peridynamics to theoretically compensate for the problems of the finite element method(FEM)in generating crack pattern images.Second,case studies are conducted with the prototype microelastic brittle(PMB),linear peridynamic solid(LPS),and viscoelastic solid(VES)models obtained by using the peridynamic theory.The case studies are performed to classify the images by using CNNs and determine the suitability of the PMB,LBS,and VES models.Finally,a regression analysis is performed on the crack pattern images with NPs to predict the crack patterns.The regression analysis results confirm that the variance decreases when the number of epochs increases by using the NPs.The training results gradually improve,and the variance ranges decrease to less than 0.035.The main finding of this study is that the NPs enable accurate predictions,even with missing or insufficient training data.The results demonstrate that if the context points are set to the 10th,100th,300th,and 784th,the training information is deliberately omitted for the context points of the 10th,100th,and 300th,and the predictions are different when the context points are significantly lower.However,the comparison of the results of the 100th and 784th context points shows that the predicted results are similar because of the Gaussian processes in the NPs.Therefore,if the NPs are employed for training,the missing information of the training data can be supplemented to predict the results.

Development and Performance Evaluation of Catalyst for Productive Ethylene Cracking Feedstock in Selective Hydrocracking of Straight Run Diesel Oil

The upgrading of diesel oil to produce ethylene rich cracking feedstock is an important and promising technical route to reduce the ratio of diesel to gasoline. In the present work, a hydrocracking catalyst suitable for selective hydrocracking of straight run diesel oil to produce high-quality ethylene cracking feedstock at low cost was developed, by optimizing the composition of catalyst support materials, using amorphous silicon aluminum and aluminum oxide with high mesopore content as the main support, and modified Y zeolite with excellent aromatic ring opening selectivity as the acidic component. The catalyst has in-depth characterized by X-ray diffraction, transmission electron microscopy, scanning electron microscopy, N2-low temperature adsorption-desorption, NH3-temperature-programmed desorption, and IR techniques. And its catalytic cracking straight run diesel oil performance was evaluated. The results show that the prepared catalyst has high polycyclic aromatic hydrocarbon ring opening cracking selectivity. However, alkanes retained in diesel distillates can achieve the goal of producing more ethylene cracking feedstocks with low BMCI value under low and moderate pressure conditions. This work may shed significant technical insight for oil refining transformation.

A Numerical Study of Wave Propagation and Cracking Processes in Rock-Like Material under Seismic Loading Based on the Bonded-Particle Model Approach

An earthquake is usually followed by a considerable number of aftershocks that play a significant role in earthquake-induced landslides,During the aftershock,the cracking process in rocks becomes more complex because of the formation of faults.In order to investigate the effects of seismic loading on the cracking processes in a specimen containing a single flaw,a numerical approach based on the bonded-particle model(BPM)was adopted to study the seismic loading applied in two orthogonal directions.The results reveal that no transmission and reflection phenomena were observable in the small specimens(76 mm×152 mm)because they were considerably smaller than the wavelength of the P-wave.Furthermore,under seismic loading,the induced crack was solely tensile in nature.Repeated axial seismic loading did not induce crack propagation after the first axial seismic loading.Cracks began to propagate only when the seismic loading direction was changed from axial to lateral,and then back to axial,ultimately resulting in the failure of the specimen.

Intensification of Ethylene Production from Naphtha via a Redox Oxy-Cracking Scheme： Process Simulations and Analysis

Ethylene production by the thermal cracking of naphtha is an energy-intensive process （up to 40 GJ heat per tonne ethylene）, leading to significant formation of coke and nitrogen oxide （NOx）, along with 1,8- 2 kg of carbon dioxide （CO2） emission per kilogram of ethylene produced, We propose an alternative pro- cess for the redox oxy-cracking （ROC） of naphtha, In this two-step process, hydrogen （H2） from naphtha cracking is selectively comhusted by a redox catalyst with its lattice oxygen first, The redox catalyst is subsequently re-oxidized by air and releases heat, which is used to satisfy the heat requirement for the cracking reactions, This intensified process reduces parasitic energy consumption and CO2 and NOx emissions, Moreover, the formation of ethylene and propylene can he enhanced due to the selective com-bustion of H2, In this study, the ROC process is simulated with ASPEN Plus^R based on experimental data from recently developed redox catalysts, Compared with traditional naphtha cracking, the ROC process can provide up to 52% reduction in energy consumption and CO2 emissions, The upstream section of the process consumes approximately 67% less energy while producing 28% more ethylene and propylene for every kilogram of naphtha feedstock,

Modeling and Optimization of a Fractionation,Absorption,and Stabilization System in an Industrial Fluid Catalytic Cracking Process

Fluid catalytic cracking(FCC)is a vitally important refinery process.The fractionation,absorption,and stabilization system in the FCC process is a significant way to obtain key products,and its parameters will directly affect the quality of the products.In this work,using industrial data from an actual FCC process,a model of the FCC fractionation,absorption,and stabilization system was developed using process simulation software.The sequence quadratic program algorithm was then used to identify the parameters of each tower,increasing the accuracy of the simulation results.Next,using this improved model,a sensitivity analysis was performed to examine the effects of different operating conditions.The pattern-search method was then used to optimize the operating parameters of the system.The results showed that the optimized model has good prediction accuracy,and using the model,it was found that changing the operation parameters could result in a 1.84%improvement in economic benefits.As such,the developed model was demonstrated to be usefully applicable to the optimization of the process operation of an FCC fractionation,absorption,and stabilization system.

Dual-radiation-chamber coordinated overall energy efficiency scheduling solution for ethylene cracking process regarding multi-parameter setting and multi-flow allocation

Ethylene cracking process is the core production process in ethylene industry,and is paid more attention to reduce high energy consumption.Because of the interdependent relationships between multi-flow allocation and multi-parameter setting in cracking process,it is difficult to find the overall energy efficiency scheduling for the purpose of saving energy.The traditional scheduling solutions with optimal economic benefit are not applicable for energy efficiency scheduling issue due to the neglecting of recycle and lost energy,as well as critical operation parameters as coil outlet pressure(COP)and dilution ratio.In addition,the scheduling solutions mostly regard each cracking furnace as an elementary unit,regardless of the coordinated operation of internal dual radiation chambers(DRC).Therefore,to improve energy utilization and production operation,a novel energy efficiency scheduling solution for ethylene cracking process is proposed in this paper.Specifically,steam heat recycle and exhaust heat loss are considered in cracking process based on 6 types of extreme learning machine(ELM)based cracking models incorporating DRC operation and three operation parameters as coil outlet temperature(COT),COP,and dilution ratio according to semi-mechanism analysis.Then to provide long-term decision-making basis for energy efficiency scheduling,overall energy efficiency indexes,including overall output per unit net energy input(OONE),output-input ratio per unit net energy input(ORNE),exhaust gas heat loss ratio(EGHL),are designed based on input-output analysis in terms of material and energy flows.Finally,a multiobjective evolutionary algorithm based on decomposition(MOEA/D)is employed to solve the formulated multi-objective mixed-integer nonlinear programming(MOMINLP)model.The validities of the proposed scheduling solution are illustrated through a case study.The scheduling results demonstrate that an optimal balance between multi-flow allocation,multi-parameter setting,and DRC coordinated operation is reached,which achieves 3.37%and 2.63%decreases in net energy input for same product output and conversion ratio,as well as the 1.56%decrease in energy loss ratio.

Research Progress in Catalytic Cracking Reaction of Tetralin and Decalin

The integrated catalytic hydrogenation and catalytic cracking process has been gradually adopted by refineries to satisfy the requirements for manufacture of light and clean petroleum products. To explore the reaction laws of hydrogenated aromatics in hydrotreated oil, the catalytic cracking reaction laws of hydrogenated aromatics have been reviewed by taking tetralin and decalin as examples of different degrees of hydrogenated aromatics. Moreover, the reaction mechanism of tetralin and decalin has been analyzed emphatically. The effects of zeolite pore structure, acid properties and process parameters on reaction laws have been analyzed carefully. It is considered that the catalytic cracking performance of hydrogenated aromatics with different hydrogen saturation degrees is quite different. It is necessary to control the hydrogenation depth, optimize the hydrocarbon composition of catalytic cracking feed materials for maximizing the yield of target products.

Behavior of Transversal Crack on Slab Corner During V-H Rolling Process

The behavior of transversal cracks on the surface of the slab corner during vertical and horizontal （V-H） rolling process with flat vertical roll and groove vertical roll was simulated by explicit dynamic finite element method. The closure and growth of crack and the contact pressure on surfaces of the crack in contacting zone between slab and roll during rolling process were analyzed. The results showed that during vertical rolling process, when the groove vertical roll is used, the maximum contact pressure on surfaces of the crack is 115 MPa, and the closure of crack is stable when the flat vertical roll is used, the maximum contact pressure on surfaces of the crack is 70 MPa, and it fluctuates greatly. During horizontal rolling process, when groove vertical roll is used, the contact pressure becomes zero which may accelerate the growth of crack when flat vertical roll is used, there is still contact pressure. The cal culated results are in good agreement with the results of test.

Cold Cracking of Flux Cored Arc Welded Armour Grade High Strength Steel Weldments

In this investigation, an attempt has been made to study the influence of welding consumables on the factors that influence cold cracking of armour grade quenched and tempered （Q＆.T） steel welds. Flux cored arc welding （FCAW） process were used making welds using austenitic stainless steel （ASS） and low hydrogen ferritic steel （LHF） consumables. The diffusible hydrogen levels in the weld metal of the ASS and LHF consumables were determined by mercury method. Residual stresses were evaluated using X-ray stress analyzer and implant test was carried out to study the cold cracking of the welds. Results indicate that ASS welds offer a greater resistance to cold cracking of armour grade Q＆T steel welds.

Characteristics of acoustic emission signals in damp cracking coal rocks

A uniaxial load experiment on coal rocks at different stress rates was carried out, based on the characteristics of acoustic emission (AE) signals in cracking coal rocks, decomposition, de-noising and reconstruction for the AE signals through wavelet packet transform for solving the current problems created by the presence of noise in AE signals and the existing problems in AE signal processing. The results show that the various characteristics of AE signals in coal rocks cracking under different situations can be clearly reflected, after the AE signals are de-noised by the wavelet packet. Compared to dry coal rocks, the number of AE occurrences in damp coal rocks was significantly reduced, as well as the average amplitude. The number of AE occurrences in damp and dry coal rocks clearly increased with increases in the loading rate, but the largest amplitude of the AE signals in damp coal rocks has been reduced. There is no clear evidence of change in dry coal rocks.

Effect of Zr content on crack formation and mechanical properties of IN738LC processed by selective laser melting

Two batches of commercial IN738LC alloy powders with different Zr contents were printed under the same parameters.The influences of Zr content(0.024 wt.% and 0.12 wt.%,respectively) in powders on crack density,distribution,formation mechanism and mechanical properties of selective laser melting(SLM)-treated parts were systematically studied.It was found that the crack density(area ratio) increases from 0.15% to 0.87% in the XOY plane and from 0.21% to 1.81% in the XOZ plane along with the Zr content increase from 0.024 wt.% to 0.12 wt.% in the original powders.Solidification cracks are formed along the epitaxially grown <001>-oriented columnar grain boundaries in molten pool center.The ultimate tensile strength of Sample 1(0.024 wt.% Zr) is 1113 MPa,and there are dimples in tensile fracture.With an increase in the Zr content to 0.12 wt.%(Sample 2),the ultimate tensile strength of Sample 2 decreases to 610 MPa,and there are numerous original cracks and exposed columnar grain boundaries in tensile fracture.The optimization of printing parameters of Sample 2 considerably increases the ultimate tensile strength by 55.2% to 947 MPa,and the plasticity is greatly improved.

Effect of gradient temperature rolling process on promoting crack healing in Q500 heavy plates

To ensure the quality of heavy plate products as determined by ultrasonic inspection, it is necessary to effectively control defects such as cracks and shrinkage cavities in heavy plates. Generally, some defects such as large size cracks exist due to insufficient deformation in the center of traditionally rolled plates. Compared with the traditional rolling process, gradient temperature rolling(GTR) process can effectively increase deformation inside heavy plates. In this study, the effect of GTR on crack healing was analyzed through a comparison experiment with the uniform temperature rolling(UTR). The results show that the GTR process could increase the plastic strain inside the heavy plate and effectively promote the healing process of the preset cracks. The degrees of crack healing at the center and quarter thickness position of the steel plate via GTR were greater than twice those of the plate via UTR. The GTR process can significantly reduce the internal defects of heavy plates and improve the defect detection level of heavy plate products. Also, The GTR process results in the formation of new crystal grains in the crack region, which is crucial to crack healing.

Distribution and State of Ni Contaminants on Resid Fluid Catalytic Cracking Catalysts—Characterization by AEM, EPMA, UV-Vis and TPR

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Prediction of crack location and propagation in stretch flanging process of aluminum alloy AA-5052 sheet using FEM simulation

The stretch flanging process is significantly affected by various geometrical,material and process parameters.The punch-die clearance and initial flange length are main parameters which have major effects on the edge crack location and strain distribution along die profile radius in the flange.Non-axisymmetric stretch flanging process of AA-5052 sheet metal blanks was carried out by numerical simulation to predict the deformation behavior of flange,location and propagation of crack in flange and to investigate the effect of punch die clearance,flange length,die and punch profile radius and friction in the stretch flanging process.The experimental investigations were made to validate the simulations results.The results reveal that the crack length increases with the increase in the flange length.It is found that the flange length has a significant effect in circumferential direction as compared with the radial direction.The punch die clearance has the most significant effect in crack propagation in comparison with flange length.The circumferential strain is found to be larger in the case of punch having the profile radius less than the die profile radius,which leads to faster edge crack propagation.A close agreement is found between simulation and experimental results in terms of location of edge crack and forming load.