# US 10,119,764 B2 · Recovery and re-use of waste energy in industrial facilities

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- Number: US 10,119,764 B2
- Document ID: US10119764B2
- Status: Granted
- Kind: B2
- Application number: 15/241,989
- Filed: 2016-08-19
- Published: 2017-03-02
- Granted: 2018-11-06
- Earliest claimed: 2015-08-24
- Assignees: Saudi Arabian Oil Company
- Applicants: Saudi Arabian Oil Company
- Inventors: Mahmoud Bahy Mahmoud Noureldin; Hani Mohammed Al Saed
- Web page: https://patentgrep.com/patent/US10119764B2

## CPC

- F28D 7/0083: {with units having particular arrangement relative to a supplementary heat exchange medium, e.g. with interleaved units or with adjacent units arranged in common flow of supplementary heat exchange medium}
- B01D 3/007: {Energy recuperation; Heat pumps}
- B01D 3/32: Other features of fractionating columns {; Constructional details of fractionating columns not provided for in groups B01D3/16 - B01D3/30}
- B01D 51/10: Conditioning the gas to be cleaned
- B01D 53/047: Pressure swing adsorption
- B01D 53/1462: {Removing mixtures of hydrogen sulfide and carbon dioxide}
- B01D 53/185: {Liquid distributors}
- B01D 53/343: {Heat recovery}
- B01D 53/48: Sulfur compounds
- B01D 53/8603: {Removing sulfur compounds}
- B01D 53/96: Regeneration, reactivation or recycling of reactants
- C01B 3/24: of hydrocarbons
- C01B 3/34: by reaction of hydrocarbons with gasifying agents
- C02F 1/586: {by removing ammoniacal nitrogen (for biological methods C02F3/00)}
- C07C 7/08: by extractive distillation
- C10G 33/06: with mechanical means, e.g. by filtration
- C10G 35/04: Catalytic reforming
- C10G 45/00: Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
- C10G 45/02: to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
- C10G 45/44: Hydrogenation of the aromatic hydrocarbons
- C10G 47/00: Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions (C10G15/00 takes precedence; destructive hydrogenation of non-melting solid carbonaceous or similar materials C10G1/06)
- C10G 65/00: Treatment of hydrocarbon oils by two or more hydrotreatment processes only
- C10G 65/12: including cracking steps and other hydrotreatment steps
- C10G 69/00: Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process (C10G67/00 takes precedence)
- C10K 3/04: reducing the carbon monoxide content {, e.g. water-gas shift [WGS]}
- C10L 3/101: {Removal of contaminants}
- C10L 3/103: {Sulfur containing contaminants}
- C10L 3/104: {Carbon dioxide}
- F01D 17/145: {by means of valves, e.g. for steam turbines (valves in general F16K)}
- F01K 3/185: {using waste heat from outside the plant (F02G5/00 takes precedence)}
- F01K 13/00: General layout or general methods of operation of complete plants
- F01K 13/02: Controlling, e.g. stopping or starting
- F01K 23/06: combustion heat from one cycle heating the fluid in another cycle
- F01K 23/064: {in combination with an industrial process, e.g. chemical, metallurgical}
- F01K 25/06: using mixtures of different fluids (plants using mixtures of steam and gas F01K21/04)
- F01K 25/08: using special vapours
- F01K 27/00: Plants for converting heat or fluid energy into mechanical energy, not otherwise provided for
- F01K 27/02: Plants modified to use their waste heat, other than that of exhaust, e.g. engine-friction heat
- F28F 9/26: Arrangements for connecting different sections of heat-exchange elements, e.g. of radiators (connecting different sections in water heaters F24H9/14 {, connecting headers with inlet or outlet fittings F28F9/0246})
- H02K 7/1823: {structurally associated with turbines or similar engines}
- B01D 2252/204: Amines
- C01B 2203/0227: containing a catalytic reforming step
- C01B 2203/0233: the reforming step being a steam reforming step
- C01B 2203/0283: containing a CO-shift step, i.e. a water gas shift step
- C01B 2203/043: Regenerative adsorption process in two or more beds, one for adsorption, the other for regeneration
- C01B 2203/127: Catalytic desulfurisation
- C02F 2101/10: Inorganic compounds
- C02F 2101/101: {Sulfur compounds}
- C02F 2101/16: Nitrogen compounds, e.g. ammonia
- C02F 2103/18: from the purification of gaseous effluents
- C02F 2103/36: from the manufacture of organic compounds
- C10G 2300/202: Heteroatoms content, i.e. S, N, O, P
- C10G 2300/207: Acid gases, e.g. H2S, COS, SO2, HCN
- C10G 2300/4006: Temperature
- C10G 2300/4056: Retrofitting operations
- C10G 2400/04: Diesel oil
- C10G 2400/30: Aromatics
- C10L 2290/06: Heat exchange, direct or indirect
- C10L 2290/541: Absorption of impurities during preparation or upgrading of a fuel
- Y02P 20/129: Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
- Y02P 30/00: Technologies relating to oil refining and petrochemical industry
- F28D: HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT (fluid heaters having heat generating means and heat transferring means F24H; furnaces F27; details of heat-exchange apparatus of general)
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C02F: TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE (separation in general B01D; special arrangements on waterborne vessels of installations for treating water, waste water or sewage, e.g. for producing fresh water, B63J; adding materials to water to prevent corrosion C23F; treating radioactively-contaminated liquids G21F9/04; regeneration of reactants for recirculation into processes, see the relevant places for the processes)
- C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10K: PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
- C10L: FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- F01K: STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES (gas-turbine or jet-propulsion plants F02; nuclear power plants, engine arrangements therein G21D)
- F28F: DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION (water and air traps, air venting F16)
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Configurations and related processing schemes of direct or indirect (or both) inter-plants heating systems synthesized for grassroots medium grade crude oil semi-conversion refineries to increase energy efficiency from specific portions of low grade waste heat sources are described. Configurations and related processing schemes of direct or indirect (or both) inter-plants heating systems synthesized for integrated medium grade crude oil semi-conversion refineries and aromatics complex for increasing energy efficiency from specific portions of low grade waste sources are also described.

## Claims

### Claim 1

A method implemented in a crude oil refining facility, the method comprising:
in a crude oil refining facility comprising a plurality of oil refining plants, each oil refining plant configured to perform at least one oil refining process, each oil refining plant comprising a plurality of interconnected oil refining sub-systems, wherein a plurality of streams at respective temperatures flow between the plurality of oil refining sub-systems:
flowing a hydrocracking plant stream, a low temperature shift (LTS) converter product stream and a diesel hydro-treating plant stream of a hydrocracking plant, a steam reforming hydrogen plant and a diesel hydro-treating plant, respectively, of the plurality of oil refining plants to one or more heat exchangers, the hydrocracking plant stream comprising at least one of a feed stream to a first reaction stage cold high pressure separator, a feed stream to a second reaction stage cold high pressure separator, a product stripper overhead stream, a diesel product stream, a kerosene pumparound stream, and a kerosene product stream;
flowing a stream from a first oil refining plant of the plurality of oil refining plants to the one or more heat exchangers, the first oil refining plant being different from the hydrocracking plant, the steam reforming hydrogen plant and the diesel hydro-treating plant and comprising a naphtha hydro-treating plant, a sour water stripper plant, an amine regeneration plant separation section, a sulfur recovery plant and a gas separation plant through which a gas separation plant stream comprising at least one of C2 to C4 flows, wherein the one or more heat exchangers transfer heat from one or more of the hydrocracking plant stream, the low temperature shift (LTS) converter product stream and the diesel hydro-treating plant stream to the stream from the first oil refining plant; and
utilizing the stream from the first oil refining plant heated by one or more of the hydrocracking plant stream, the low temperature shift (LTS) converter product stream and the diesel hydro-treating plant stream in an oil refining process at the first oil refining plant.

### Claim 2 (depends on 1)

The method claim 1, wherein the one or more heat exchangers indirectly transfer heat from one or more of the hydrocracking plant stream, the low temperature shift (LTS) converter product stream and the diesel hydro-treating plant stream to the stream from the first oil refining plant.

### Claim 3 (depends on 2)

The method of claim 2, wherein the one or more heat exchangers indirectly transfer heat through a buffer fluid using one or more of the hydrocracking plant stream, the low temperature shift (LTS) converter product stream and the diesel hydro-treating plant stream.

### Claim 4 (depends on 3)

The method of claim 3, wherein the buffer fluid comprises at least one of oil or water.

### Claim 5 (depends on 3)

The method of claim 3, wherein the one or more heat exchangers indirectly transfer heat through the buffer fluid using one or more of the hydrocracking plant stream, the low temperature shift (LTS) converter product stream and the diesel hydro-treating plant stream by:
heating, in a first heat exchanger, a first buffer fluid stream using the hydrocracking plant diesel product stream in the hydrocracking plant;
heating, in a second heat exchanger, a second buffer fluid stream using the feed stream to the second reaction stage cold high pressure separator in the hydrocracking plant;
heating, in a third heat exchanger, a third buffer fluid stream using the feed stream to the first reaction stage cold high pressure separator in the hydrocracking plant;
heating, in a fourth heat exchanger, a fourth buffer fluid stream using the product stripper overhead stream in the hydrocracking plant;
heating, in a fifth heat exchanger, a fifth buffer fluid stream using the kerosene pumparound stream in the hydrocracking plant;
heating, in a sixth heat exchanger, a sixth buffer fluid stream using the kerosene product stream in the hydrocracking plant;
heating, in a seventh heat exchanger, a seventh buffer fluid stream using the low temperature shift converter product stream in the steam reforming hydrogen plant;
heating, in an eighth heat exchanger, an eight buffer fluid stream using a diesel stripper overhead stream in the diesel hydro-treating plant; and
heating, in a ninth heat exchanger, a ninth buffer fluid stream using a diesel stripper bottoms stream in the diesel hydro-treating plant.

### Claim 6 (depends on 5)

The method of claim 5, further comprising combining the heated first buffer fluid stream exiting the first heat exchanger, the heated second buffer fluid stream exiting the second heat exchanger, the heated third buffer fluid stream exiting the third heat exchanger, the heated fourth buffer fluid stream exiting the fourth heat exchanger, the heated fifth buffer fluid stream exiting the fifth heat exchanger, the heated sixth buffer fluid stream exiting the sixth heat exchanger, the heated seventh buffer fluid stream exiting the seventh heat exchanger, the heated eight buffer fluid stream exiting the eighth heat exchanger, and the heated ninth buffer fluid stream exiting the ninth heat exchanger resulting in a combined heated buffer fluid.

### Claim 7 (depends on 6)

The method of claim 6, further comprising:
flowing the combined heated buffer fluid to the naphtha hydro-treating plant;
heating, in a tenth heat exchanger, a naphtha splitter bottoms stream in the naphtha hydro-treating plant using the combined heated buffer fluid;
flowing the combined heated buffer fluid to a sour water stripper bottoms in the sour water stripper plant;
heating, in an 11th heat exchanger, a sour water stripper bottoms stream in the sour water stripper plant using the combined heated buffer fluid;
flowing the combined heated buffer fluid to the sulfur recovery plant;
heating, in a 12th heat exchanger, an amine regenerator bottoms stream in the sulfur recovery plant using the combined heated buffer fluid;
flowing the combined heated buffer fluid to the amine regeneration plant separation section;
heating, in a 13th heat exchanger, an acid gas regenerator bottoms stream in the amine regeneration plant separation section using the combined heated buffer fluid;
flowing the combined heated buffer fluid to the gas separation plant;
heating, in a 14th heat exchanger, a C3/C4 splitter bottoms stream in the gas separation plant using the combined heated buffer fluid; and
heating, in the 14th heat exchanger, a de-ethanizer bottoms stream using the combined heated buffer fluid.

### Claim 8 (depends on 7)

The method of claim 7, wherein the first heat exchanger, the second heat exchanger, the third heat exchanger, the fourth heat exchanger, the fifth heat exchanger, the sixth heat exchanger, the seventh heat exchanger, the eighth heat exchanger and the ninth heat exchanger are fluidically coupled to each other in parallel.

### Claim 9 (depends on 8)

The method of claim 8, wherein the tenth heat exchanger is fluidically coupled in series with a combination of the first heat exchanger, the second heat exchanger, the third heat exchanger, the fourth heat exchanger, the fifth heat exchanger, the sixth heat exchanger, the seventh heat exchanger, the eighth heat exchanger and the ninth heat exchanger.

### Claim 10 (depends on 9)

The method of claim 9, wherein the tenth heat exchanger, 11th heat exchanger, the 12th heat exchanger, the 13th heat exchanger, the 14th heat exchanger and the 15th heat exchanger are fluidically coupled to each other in series.

### Claim 11 (depends on 9)

The method of claim 9, wherein the combined heated buffer fluid from the naphtha hydro-treating plant is flowed to the sour water stripper plant, then to the sulfur recovery plant, then to the amine regeneration plant separation section, and then to the gas separation plant.

### Claim 12 (depends on 1)

The method of claim 1, further comprising:
directly heating a first subset of the plurality of streams in the plurality of plants using one or more of the hydrocracking plant stream, the hydro-treating plant stream and the low temperature shift (LTS) converter product stream; and
indirectly heating a second subset of the plurality of streams in the plurality of plants using one or more of the hydrocracking plant stream, the hydro-treating plant stream and the low temperature shift (LTS) converter product stream.

### Claim 13 (depends on 12)

The method of claim 12, wherein indirectly heating the second subset of the plurality of streams comprises heating the second subset of the plurality of streams through a buffer fluid using one or more of the hydrocracking plant stream, the hydro-treating plant stream and the low temperature shift (LTS) converter product stream.

### Claim 14 (depends on 13)

The method of claim 13, wherein the buffer fluid comprises at least one of oil or water.

### Claim 15 (depends on 13)

The method of claim 13, wherein the second subset comprises a sour water stripper plant stream, a sulfur recovery plant stream, an acid gas removal stream, and the gas separation plant stream, and wherein indirectly heating the second subset using the buffer fluid comprises:
heating, in a first heat exchanger, a first buffer fluid stream using the hydrocracking plant diesel product stream in the hydrocracking plant;
heating, in a second heat exchanger, a second buffer fluid stream using the feed stream to the second reaction stage cold high pressure separator in the hydrocracking plant;
heating, in a third heat exchanger, a third buffer fluid stream using the feed stream to the first reaction stage cold high pressure separator in the hydrocracking plant;
heating, in a fourth heat exchanger, a fourth buffer fluid stream using the product stripper overhead stream in the hydrocracking plant;
heating, in a fifth heat exchanger, a fifth buffer fluid stream using the kerosene pumparound stream in the hydrocracking plant;
heating, in a sixth heat exchanger, a sixth buffer fluid stream using the kerosene product stream in the hydrocracking plant;
heating, in a seventh heat exchanger, a seventh buffer fluid stream using the low temperature shift converter product stream in the steam reforming hydrogen plant;
heating, in an eighth heat exchanger, an eight buffer fluid stream using a diesel stripper overhead stream in the diesel hydro-treating plant; and
heating, in a ninth heat exchanger, a ninth buffer fluid stream using a diesel stripper bottoms stream in the diesel hydro-treating plant.

### Claim 16 (depends on 15)

The method claim 15, further comprising:
combining the heated first buffer fluid stream exiting the first heat exchanger, the heated second buffer fluid stream exiting the second heat exchanger, the heated third buffer fluid stream exiting the third heat exchanger, the heated fourth buffer fluid stream exiting the fourth heat exchanger, the heated fifth buffer fluid stream exiting the fifth heat exchanger, the heated sixth buffer fluid stream exiting the sixth heat exchanger, the heated seventh buffer fluid stream exiting the seventh heat exchanger, the heated eight buffer fluid stream exiting the eighth heat exchanger, and the heated ninth buffer fluid stream exiting the ninth heat exchanger resulting in a combined heated buffer fluid.

### Claim 17 (depends on 16)

The method of claim 16, further comprising:
flowing the combined heated buffer fluid to the sour water stripper plant;
heating, in a tenth heat exchanger, a sour water stripper stream in the sour water stripper plant using the combined heated buffer fluid;
flowing the combined heated buffer fluid to the sulfur recovery plant;
heating, in an 11th heat exchanger, a sulfur recovery plant amine regenerator bottoms stream in the sulfur recovery plant using the combined heated buffer fluid;
flowing the combined heated buffer fluid to the amine regeneration plant separation section; and
heating, in a twelfth heat exchanger, an acid gas regenerator bottoms stream in the amine regeneration plant separation section using the combined heated buffer fluid.

### Claim 18 (depends on 17)

The method of claim 17, wherein the combined heated buffer fluid is flowed to the sour water stripper plant, then to the sulfur recovery plant, and then to the amine regeneration plant separation section.

### Claim 19 (depends on 15)

The method of claim 15, wherein the first subset comprises a naphtha splitter bottoms stream in the naphtha hydro-treating plant directly heated using the hydrocracking plant stream and the hydro-treating plant stream by:
heating, in heat exchanger A, a first branch of the naphtha splitter bottoms stream using a diesel hydro-treating plant stream using a diesel stripper overhead stream in the diesel hydro-treating plant;
heating, in heat exchanger B, a second branch of the naphtha splitter bottoms stream using the diesel hydro-treating plant stream using a stripper bottoms stream in the diesel hydro-treating plant;
heating, in heat exchanger C, a third branch of the naphtha splitter bottoms stream using a hydrocracking plant stream using a product stripper overhead stream in the hydrocracking plant;
heating, in heat exchanger D, a fourth branch of the naphtha splitter bottoms stream using the hydrocracking plant stream using a diesel product stream in the hydrocracking plant;
heating, in heat exchanger E, a fifth branch of the naphtha splitter bottoms stream using the hydrocracking plant stream using a kerosene product stream in the hydrocracking plant;
heating, in heat exchanger F, a sixth branch of the naphtha splitter bottoms stream using the hydrocracking plant stream using a kerosene pumparound stream in the hydrocracking plant stream;
combining the heated first branch, the heated second branch, the heated third branch, the heated fourth branch, the heated fifth branch and the heated sixth branch resulting in a combined heated naphtha splitter bottoms stream; and
flowing the heated naphtha splitter bottoms stream to the naphtha splitter bottoms in the naphtha hydro-treating plant.

### Claim 20 (depends on 19)

The method of claim 19, wherein the heat exchanger A, the heat exchanger B, the heat exchanger C, the heat exchanger D, the heat exchanger E and the heat exchanger F are fluidically coupled to each other in parallel.

### Claim 21 (depends on 19)

The method of claim 19, wherein the first heat exchanger is fluidically coupled in series with the heat exchanger D, wherein the fourth heat exchanger is fluidically coupled in series with the heat exchanger C, wherein the fifth heat exchanger is fluidically coupled in series with the heat exchanger F, wherein the sixth heat exchanger is fluidically coupled in series with the heat exchanger E, wherein the eighth heat exchanger is coupled in series with the heat exchanger A, wherein the ninth heat exchanger is fluidically coupled in series with the heat exchanger B.

### Claim 22 (depends on 19)

The method of claim 19, wherein the first heat exchanger, the second heat exchanger, the third heat exchanger, the fourth heat exchanger, the fifth heat exchanger, the sixth heat exchanger, the seventh heat exchanger, the eighth heat exchanger and the ninth heat exchanger are fluidically coupled to each other in parallel.

### Claim 23 (depends on 22)

The method of claim 22, wherein the hydrocracking plant stream used to heat the fifth branch of the naptha splitter bottom stream in heat exchanger E comprises the kerosene product stream, and wherein the method further comprises:
flowing the kerosene product stream exiting heat exchanger E to the gas separation plant;
heating, in a 13th heat exchanger, a first branch of a C3/C4 splitter bottoms stream in the gas separation plant using the kerosene product stream exiting heat exchanger E;
flowing the diesel hydro-treating plant stream exiting heat exchanger B to the gas separation plant;
heating, in a 14th heat exchanger, a second branch of a C3/C4 splitter bottoms stream in the gas separation plant using the diesel hydro-treating plant stream exiting heat exchanger B;
flowing the low temperature shift converter product stream in the steam reforming hydrogen plant exiting the seventh heat exchanger to the gas separation plant; and
heating, in a 15th heat exchanger, a de-ethanizer bottoms stream using the low temperature shift converter product stream in the steam reforming hydrogen plant exiting the seventh heat exchanger.

### Claim 24 (depends on 23)

The method of claim 23, wherein the tenth heat exchanger is fluidically coupled in series with a combination of the first heat exchanger, the second heat exchanger, the third heat exchanger, the fourth heat exchanger, the fifth heat exchanger, the sixth heat exchanger, the seventh heat exchanger, the eighth heat exchanger and the ninth heat exchanger.

### Claim 25 (depends on 24)

The method of claim 24, wherein the tenth heat exchanger, the 11th heat exchanger, the 12th heat exchanger, the 13th heat exchanger, and the 14th heat exchanger are fluidically coupled to each other in series.

### Claim 26 (depends on 25)

The method of claim 25, wherein the seventh heat exchanger and the 15th heat exchanger are fluidically coupled to each other in series.