Process and system for conversion of crude oil to petrochemicals and fuel products integrating vacuum gas oil hydrocracking and steam cracking

Patent metadata

Field	Value
Publication number	US-10472579-B2
Application number	US-201715817128-A
Country	US
Kind code	B2
Filing date	Nov 17, 2017
Priority date	Nov 21, 2016
Publication date	Nov 12, 2019
Grant date	Nov 12, 2019

Abstract

Process scheme configurations are disclosed that enable conversion of crude oil feeds with several processing units in an integrated manner into petrochemicals. The designs utilize minimum capital expenditures to prepare suitable feedstocks for the steam cracker complex. The integrated process for converting crude oil to petrochemical products including olefins and aromatics, and fuel products, includes mixed feed steam cracking and gas oil steam cracking. Feeds to the mixed feed steam cracker include light products and naphtha from hydroprocessing zones within the battery limits, recycle streams from the C3 and C4 olefins recovery steps, and raffinate from a pyrolysis gasoline aromatics extraction zone within the battery limits. Feeds to the gas oil steam cracker include unconverted oil intermediates from vacuum gas oil hydrotreating.

First claim

The invention claimed is:

1. An integrated process for producing petrochemicals and fuel products from a crude oil feed comprising:
separating from the crude oil feed, in an atmospheric distillation unit (ADU), at least
a first ADU fraction comprising straight run naphtha,
a second ADU fraction comprising at least a portion of middle distillates from the crude oil feed, and
a third ADU fraction comprising atmospheric residue;

separating from the third ADU fraction, in a vacuum distillation unit (VDU), at least
a first VDU fraction comprising vacuum gas oil;

hydroprocessing in a distillate hydroprocessing (DHP) zone middle distillates from the second ADU fraction, and recovering at least a first DHP fraction and a second DHP fraction, wherein the first DHP fraction comprises naphtha and the second DHP fraction is used for diesel fuel production;
hydrocracking in a gas oil hydrocracking (GOHCK) zone vacuum gas oil from the first VDU fraction, and recovering a first GOHCK fraction containing components boiling at or below an atmospheric residue end boiling point and including LPG, naphtha and middle distillate range components, and unconverted gas oil;
steam cracking, in a mixed feed steam cracking (MFSC) zone, naphtha from the first ADU fraction and raffinate derived from an aromatics extraction zone, and, in a gas oil steam cracking (GOSC) zone, unconverted oil, wherein steam cracking operates under conditions effective to recover at least a mixed product stream H2, methane, ethane, ethylene, mixed C3s and mixed C4s; pyrolysis gas; and pyrolysis oil;
recovering, from the mixed product stream, H2, methane, non-olefinic C2-C4s, and petrochemicals ethylene, propylene and butylenes,
hydroprocessing pyrolysis gas from steam cracking in a naphtha hydroprocessing zone, and recovering hydrotreated pyrolysis gas; and
separating aromatics from hydrotreated pyrolysis gas in the aromatics extraction zone for recovery of petrochemical aromatic products, and aromatics extraction zone raffinate, wherein the raffinate derived from aromatics extraction is all or a portion of the aromatics extraction zone raffinate.

2. The process as in claim 1 , wherein the GOHCK zone is a two-stage with recycle configuration operating in a full conversion mode of operation, in the presence of hydrocracking catalyst to convert 78-99 wt % of feed to the GOHCK zone into the first GOHCK fraction.

3. The process as in claim 2 , wherein the two-stage with recycle configuration includes a first stage reactor and a second stage reactor, and wherein operating conditions in the first stage reactor include:
a reactor inlet temperature (° C.) in the range of from about 340-502;
a reactor outlet temperature (° C.) in the range of from about 350-516;
a start of run (SOR) reaction temperature (° C.), as a weighted average bed temperature (WABT), in the range of from about 310-475;
an end of run (EOR) reaction temperature (° C.), as a WABT, in the range of from about 338-516;
a reaction inlet pressure (barg) in the range of from about 100-180;
a reaction outlet pressure (barg) in the range of from about 90-170;
a hydrogen partial pressure (barg) (outlet) in the range of from about 90-137;
a hydrogen treat gas feed rate (SLt/Lt) up to about 1050;
a hydrogen quench gas feed rate (SLt/Lt) up to about 1100;
a make-up hydrogen feed rate (SLt/Lt) up to about 564; and
a liquid hourly space velocity (h −1 ), on a fresh feed basis relative to the hydrotreating catalysts, in the range of from about 0.1-10.0;

and
operating conditions in the second stage reactor include:
a reactor inlet temperature (° C.) in the range of from about 340-502;
a reactor outlet temperature (° C.) in the range of from about 350-516;
a start of run (SOR) reaction temperature (° C.), as a weighted average bed temperature (WABT), in the range of from about 310-475;
an end of run (EOR) reaction temperature (° C.), as a WABT, in the range of from about 338-516;
a reaction inlet pressure (barg) in the range of from about 80-145;
a reaction outlet pressure (barg) in the range of from about 75-137;
a hydrogen partial pressure (barg) (outlet) in the range of from about 90-145;
a hydrogen treat gas feed rate (SLt/Lt) up to about 910;
a hydrogen quench gas feed rate (SLt/Lt) up to about 980;
a make-up hydrogen feed rate (SLt/Lt) up to about 451; and
a liquid hourly space velocity (h −1 ), on a fresh feed basis relative to the hydrotreating catalysts, in the range of from about 0.1-10.0.

4. The process as in claim 1 , wherein the GOHCK zone is a once-through series configuration operating in a partial conversion mode of operation, in the presence of hydrocracking catalyst, to convert 48-82 wt % of feed to the GOHCK zone into the first GOHCK fraction.

5. The process as in claim 4 , wherein once-through series configuration includes a first reactor and a second reactor, and wherein operating conditions in the first reactor include:
a reactor inlet temperature (° C.) in the range of from about 340-502;
a reactor outlet temperature (° C.) in the range of from about 350-516;
a start of run (SOR) reaction temperature (° C.), as a weighted average bed temperature (WABT), in the range of from about 310-475;
an end of run (EOR) reaction temperature (° C.), as a WABT, in the range of from about 338-516;
a reaction inlet pressure (barg) in the range of from about 100-165;
a reaction outlet pressure (barg) in the range of from about 92-150;
a hydrogen partial pressure (barg) (outlet) in the range of from about 80-120;
a hydrogen treat gas feed rate (SLt/Lt) up to about 668;
a hydrogen quench gas feed rate (SLt/Lt) up to about 819;
a make-up hydrogen feed rate (SLt/Lt) up to about 271; and
a liquid hourly space velocity (h −1 ), on a fresh feed basis relative to the hydrotreating catalysts, in the range of from about 0.1-10.0;

and
operating conditions in the second reactor include:
a reactor inlet temperature (° C.) in the range of from about 340-502;
a reactor outlet temperature (° C.) in the range of from about 350-516;
a start of run (SOR) reaction temperature (° C.), as a weighted average bed temperature (WABT), in the range of from about 310-475;
an end of run (EOR) reaction temperature (° C.), as a WABT, in the range of from about 338-516;
a reaction inlet pressure (barg) in the range of from about 90-150;
a reaction outlet pressure (barg) in the range of from about 85-140;
a hydrogen partial pressure (barg) (outlet) in the range of from about 80-130;
a hydrogen treat gas feed rate (SLt/Lt) up to about 890;
a hydrogen quench gas feed rate (SLt/Lt) up to about 850;
a make-up hydrogen feed rate (SLt/Lt) up to about 372; and
a liquid hourly space velocity (h −1 ), on a fresh feed basis relative to the hydrotreating catalysts, in the range of from about 0.1-10.0.

6. The process as in claim 1 , wherein the GOHCK zone is a once-through (single stage without recycle) configuration operating in a partial conversion in the presence of hydrocracking catalyst to convert 48-82 wt % of feed to the GOHCK zone into the first GOHCK fraction.

7. The process as in claim 6 , wherein the once-through (single stage without recycle) configuration operating conditions include:
a reactor inlet temperature (° C.) in the range of from about 340-502;
a reactor outlet temperature (° C.) in the range of from about 350-516;
a start of run (SOR) reaction temperature (° C.), as a weighted average bed temperature (WABT), in the range of from about 310-475;
an end of run (EOR) reaction temperature (° C.), as a WABT, in the range of from about 338-516;
a reaction inlet pressure (barg) in the range of from about 100-165;
a reaction outlet pressure (barg) in the range of from about 92-150;

Assignees

• Saudi Arabian Oil Co

Inventors

• Al-Ghamdi Mohammed Saeed

Classifications

• C10G2300/104

  Light gasoline having a boiling range of about 20 - 100 °C · CPC title

• C10G55/06 Primary

  including at least one catalytic cracking step · CPC title

• C10G47/02

  characterised by the catalyst used · CPC title

• C10G7/00

  Distillation of hydrocarbon oils · CPC title

• C10G2300/1051

  Kerosene having a boiling range of about 180 - 230 °C · CPC title