Integrated hydrotreating and steam pyrolysis process for the direct processing of a crude oil to produce olefinic and aromatic petrochemicals

Patent metadata

Field	Value
Publication number	US-11168271-B2
Application number	US-201816480469-A
Country	US
Kind code	B2
Filing date	Feb 2, 2018
Priority date	Feb 2, 2017
Publication date	Nov 9, 2021
Grant date	Nov 9, 2021

Abstract

An integrated hydrotreating and steam pyrolysis process for the direct processing of a crude oil to produce olefinic and aromatic petrochemicals by separating the crude oil into light components and heavy components.

First claim

The invention claimed is:

1. An integrated hydrotreating and steam pyrolysis process for the direct processing of a crude oil to produce olefinic and aromatic petrochemicals, the process comprising the sequential steps of:
(a1) separating the crude oil into light components and heavy components, wherein the lower boiling point of the boiling point range of said heavy components is 350° C.;
(b1) charging the heavy components and hydrogen to a hydroprocessing zone operating under conditions effective to produce a hydroprocessed effluent having a reduced content of contaminants, an increased paraffinicity, reduced Bureau of Mines Correlation Index, and an increased American Petroleum Institute gravity;
(c1) charging the hydroprocessed effluent and steam to a convection section of a steam pyrolysis zone;
(d1) heating the mixture from step (c1) and passing it to a vapor-liquid separation section;
(e1) removing from the steam pyrolysis zone a residual portion from the vapor-liquid separation section;
(f1) charging light components from step (a1), a light portion from the vapor-liquid separation section, and steam to a steam pyrolysis zone for thermal cracking;
(g1) recovering a mixed product stream from the steam pyrolysis zone;
(h1) separating the thermally cracked mixed product stream;
(i1) purifying hydrogen recovered in step (h1) and recycling it to step (b1);
(j1) recovering olefins and aromatics from the separated mixed product stream; and

(k1) recovering pyrolysis fuel oil from the separated mixed product stream;
wherein step (h1) comprises: compressing the thermally cracked mixed product stream with plural compression stages; subjecting the compressed thermally cracked mixed product stream to caustic treatment to produce a thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide; compressing the thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide; dehydrating the compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide; recovering hydrogen from the dehydrated compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide; and obtaining olefins and aromatics as in step (j1) and pyrolysis fuel oil as in step (k1) from the remainder of the dehydrated compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide; and
wherein step (i1) comprises purifying recovered hydrogen from the dehydrated compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide for recycle to the hydroprocessing zone.

2. The integrated process of claim 1 , wherein recovering hydrogen from the dehydrated compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide further comprises separately recovering methane for use as fuel for burners and/or heaters in the thermal cracking step.

3. The integrated process of claim 1 wherein separating the heated hydroprocessed effluent into a vapor fraction and a liquid fraction is with a vapor-liquid separation device based on physical and mechanical separation.

4. An integrated hydroprocessing, steam pyrolysis and resid hydrocracking process for direct conversion of crude oil to produce olefinic and aromatic petrochemicals, the process comprising:
(a2) hydroprocessing the crude oil in the presence of hydrogen under conditions effective to produce a hydroprocessed effluent having a reduced content of contaminants, an increased paraffinicity, reduced Bureau of Mines Correlation Index, and an increased American Petroleum Institute gravity, wherein the hydroprocessing zone consists of a hydroprocessing zone more than one bed containing an effective amount of hydrodemetallization catalyst, and more than one bed containing an effective amount of hydroprocessing catalyst having hydrodearomatization, hydrodenitrogenation, hydrodesulfurization and hydrocracking functions;
(b2) thermally cracking said hydroprocessed effluent in the presence of steam in a steam pyrolysis zone under conditions effective to produce a mixed product stream;
(c2) processing heavy components derived from the mixed product stream, in a resid hydrocracking zone to produce resid intermediate product, wherein said resid hydrocracking zone is an ebullated bed reactor, wherein the ebullated bed reactor comprises a catalyst comprising at least one element selected from the group consisting of Co, Mo and Ni on an alumina support and process conditions comprise a temperature of 350° C. and a pressure of 5-25 MPa gauge;
(d2) conveying the resid intermediate product to the step of thermally cracking; and
(e2) recovering olefins and aromatics from the mixed product stream; wherein the catalyst is continuously replaced;
(f2) recovering pyrolysis fuel oil from the combined mixed product stream as at least a portion of the heavy components cracked in step (c);
(g2) separating the hydroprocessed effluent from step (a) into a vapor phase and a liquid phase in a vapor-liquid separation zone, wherein the vapor phase is thermally cracked in step (b), and at least a portion of the liquid phase is processed in step (c); and
(h2) heating hydroprocessed effluent in a convection section of the steam pyrolysis zone, separating the heated hydroprocessed effluent into a vapor phase and a liquid phase, passing the vapor phase to a pyrolysis section of the steam pyrolysis zone, and discharging the liquid phase for use as at least a portion of the heavy components processed in step (c2).

5. The integrated process of claim 4 , wherein separating the heated hydroprocessed effluent into a vapor phase and a liquid phase is with a vapor-liquid separation device based on physical and mechanical separation.

6. The integrated process of claim 4 , further comprising the step of subjecting the compressed thermally cracked mixed product stream to caustic treatment to produce a thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide.

7. The integrated process according to claim 4 , further comprising the step of recovering hydrogen from the dehydrated compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide.

8. The integrated process according to claim 4 , further including the steps of separating the hydroprocessed effluents in a high pressure separator to recover a gas portion that is cleaned and recycled to the hydroprocessing zone as an additional source of hydrogen, and a liquid portion, and separating the liquid portion derived from the high pressure separator into a gas portion and a liquid portion in a low pressure separator, wherein the liquid portion derived from the low pressure separator is the feed to the thermal cracking step and the gas portion derived from the low pressure separator is combined with the combined product stream after the steam pyrolysis zone and before separation in step (e2).

9. An integrated hydroprocessing, steam pyrolysis and slurry hydroprocessing process for direct conversion of crude oil to produce olefinic and aromatic petrochemicals, the process consisting of the steps of:
(a3) hydroprocessing the crude oil and a slurry process product in the presence of hydrogen under conditions effective to produce a hydroprocessed effluent having a reduced content of contaminants, an increased paraffinicity, reduced Bureau of Mines Correlation Index, and an increased American Petroleum Institute gravity, wherein the hydroprocessing zone includes plural reaction vessels each containing catalyst beds of different f

Assignees

• Sabic Global Technologies Bv

Inventors

• Oprins Arno Johannes Maria
• Ward Andrew Mark
• Velasco Pelaez Raul
• Schaerlaeckens Egidius Jacoba Maria
• Van Willigenburg Joris

Classifications

• C10G69/06 Primary

  including at least one step of thermal cracking in the absence of hydrogen · CPC title

• C10G2300/308

  Gravity, density, e.g. API · CPC title

• C10G9/36

  with heated gases or vapours · CPC title

• C10G45/00

  Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds · CPC title

• C10G47/26

  suspended in the oil, e.g. slurries · CPC title