Systems and processes for direct crude oil upgrading to hydrogen and chemicals

Patent metadata

Field	Value
Publication number	US-11279891-B2
Application number	US-202016810596-A
Country	US
Kind code	B2
Filing date	Mar 5, 2020
Priority date	Mar 5, 2020
Publication date	Mar 22, 2022
Grant date	Mar 22, 2022

Abstract

Systems and methods for direct crude oil upgrading to hydrogen and chemicals including separating an inlet hydrocarbon stream into a light fraction and a heavy fraction comprising diesel boiling point temperature range material; producing from the light fraction syngas comprising H2 and CO; reacting the CO produced; producing from the heavy fraction and separating CO2, polymer grade ethylene, polymer grade propylene, C4 compounds, cracking products, light cycle oils, and heavy cycle oils; collecting and purifying the CO2 produced from the heavy fraction; processing the C4 compounds to produce olefinic oligomerate and paraffinic raffinate; separating the cracking products; oligomerizing a light cut naphtha stream; hydrotreating an aromatic stream; hydrocracking the light cycle oils to produce a monoaromatics product stream; gasifying the heavy cycle oils; reacting the CO produced from gasifying the heavy cycle oils; collecting and purifying the CO2; and processing and separating produced aromatic compounds into benzene and paraxylene.

First claim

The invention claimed is:

1. A method for hydrocarbon separation and upgrading, the method comprising the steps of:
separating an inlet hydrocarbon stream into a light fraction comprising naphtha boiling point temperature range material and a heavy fraction comprising diesel boiling point temperature range material;
producing from the light fraction syngas comprising H 2 and CO;
reacting the CO produced from the light fraction via at least one reaction selected from the group consisting of: carbonylation, polymerization, and water-gas shift;
producing from the heavy fraction and separating CO 2 , polymer grade ethylene, polymer grade propylene, C 4 compounds, cracking products comprising naphtha boiling point temperature range products with olefins and aromatics, light cycle oils, and heavy cycle oils;
collecting and purifying the CO 2 produced from the heavy fraction;
processing the C 4 compounds to produce olefinic oligomerate and paraffinic raffinate, the paraffinic raffinate being used to produce hydrogen;
separating the cracking products comprising naphtha boiling point temperature range products with olefins and aromatics into a light cut naphtha stream including C 5 and C 6 olefins and an aromatic stream comprising aromatic compounds;
oligomerizing the light cut naphtha stream;
hydrotreating the aromatic stream;
hydrocracking the light cycle oils to produce a monoaromatics product stream;
gasifying the heavy cycle oils to produce hydrogen, CO, and CO 2 ;
reacting the CO produced from gasifying the heavy cycle oils via at least one reaction selected from the group consisting of: carbonylation, polymerization, and water-gas shift;
collecting and purifying the CO 2 produced from gasifying the heavy cycle oils; and
processing and separating produced aromatic compounds into benzene and paraxylene.

2. The method according to claim 1 , wherein the inlet hydrocarbon stream comprises at least one component selected from the group consisting of: crude oil and gas condensates.

3. The method according to claim 1 , wherein gasoline and diesel are not final products of the method.

4. The method according to claim 1 , wherein greater than about 90 wt. % by mass of the CO 2 and greater than about 90 wt. % by mass of the CO produced in the method are captured and further processed to other compounds.

5. The method according to claim 1 , further comprising the step of collecting and purifying CO 2 produced during the step of producing from the light fraction syngas comprising H 2 and CO.

6. The method according to claim 1 , further comprising the step of processing at least a portion of the produced CO 2 in at least one process selected from the group consisting of: dry reforming; steam reforming, and hydrogenation.

7. The method according to claim 1 , further comprising the step of processing at least a portion of the produced CO 2 to produce at least one product selected from the group consisting of: a synthetic fuel; syngas comprising H 2 and CO; and olefins.

8. The method according to claim 1 , wherein the step of separating the inlet hydrocarbon stream comprises the use of at least one unit selected from the group consisting of: a flash drum, a distillation-based separation unit, and a cyclonic vapor-liquid separation unit.

9. The method according to claim 1 , where the steps of reacting the CO produced from the light fraction and reacting the CO produced from gasifying the heavy cycle oils include the step of producing adipic acid via carbonylation of butadiene.

10. The method according to claim 1 , wherein the step of producing from the light fraction syngas comprising H 2 and CO comprises the use of at least one unit selected from the group consisting of: a steam reforming unit, a partial oxidation unit, and an auto-thermal reforming unit.

11. The method according to claim 1 , wherein the step of producing from the heavy fraction is carried out using a high-severity fluidized catalytic cracking system comprising a downflow reactor.

12. The method according to claim 1 , wherein a portion of H 2 produced in the method is used internally for hydrotreating.

13. The method according to claim 1 , wherein the step of hydrocracking the light cycle oils includes hydrocracking and reforming reactions.

14. The method according to claim 1 , further comprising the step of processing the monoaromatics product stream via trans-alkylation to convert toluene and C 9 -C 11 aromatics into benzene and mixed xylenes.

15. The method according to claim 1 , wherein the CO 2 produced from the heavy fraction includes CO 2 produced from coke burned in a regenerator of a catalytic cracking system.

16. The method according to claim 1 , wherein at least a portion of the heavy cycle oils produced from the heavy fraction is utilized to provide energy to the method.

17. The method according to claim 1 , wherein the step of producing from the light fraction syngas comprising H 2 and CO further comprises producing hydrogen from at least one stream comprising saturated C 1 to C 4 compounds.

18. The method according to claim 1 , wherein the step of processing and separating produced aromatic compounds into benzene and para-xylene further produces heavy aromatics which are recycled to the step of hydrocracking the light cycle oils or gasifying the heavy cycle oils.

19. A system for hydrocarbon separation and upgrading, the system comprising:
an inlet hydrocarbon stream;
a feed inlet splitter operable to separate the inlet hydrocarbon stream into a light fraction comprising naphtha boiling point temperature range material and a heavy fraction comprising diesel boiling point temperature range material;
a hydrogen production unit operable to produce from the light fraction syngas comprising H 2 and CO;
a carbon reaction unit operable to react the CO produced from the light fraction via at least one reaction selected from the group consisting of: carbonylation, polymerization, and water-gas shift;
a high-severity fluidized catalytic cracking (HS-FCC) unit operable to produce from the heavy fraction CO 2 , polymer grade ethylene, polymer grade propylene, C 4 compounds, cracking products comprising naphtha boiling point temperature range products with olefins and aromatics, light cycle oils, and heavy cycle oils;
a CO 2 collection and processing unit operable to collect and purifying the CO 2 produced from the heavy fraction;
an oligomerization unit operable to process the C 4 compounds to produce olefinic oligomerate and paraffinic raffinate, the paraffinic raffinate being used to produce hydrogen in the hydrogen production unit;
a cracked naphtha splitter operable to separate the cracking products comprising naphtha boiling point temperature range products with olefins and aromatics into a light cut naphtha stream including C 5 and C 6 olefins and an aromatic stream comprising aromatic compounds, wherein the oligomerization unit is operable to oligomerize the light cut naphtha stream;
a heavy naphtha selective hydrotreating unit operable to hydrotreat the aromatic stream;
a cycle oils hydrocracker unit operable to hydrocrack the light cycle oils to produce a monoaromatics product stream;
a gasifier unit operable to gasify the heavy cycle oils to produce hydrogen, CO, and CO 2 , wherein the carbon reaction unit is operable to react the CO produced from gasifying the heavy cycle oils via at least one reaction selected from the group consisting of: carbonylation, polymerization, and water-gas shift, wherein the CO 2 collection and pro

Assignees

• Saudi Arabian Oil Co

Inventors

• Harale Aadesh
• Abba Ibrahim
• Khowaiter Ahmad
• Bourane Abdennour
• Jamal Aqil
• Younes Mourad

Classifications

• C10K3/04

  reducing the carbon monoxide content {, e.g. water-gas shift [WGS]} · CPC title

• C10J3/00 Primary

  Production of combustible gases containing carbon monoxide from solid carbonaceous fuels (destructive distillation processes C10B) · CPC title

• C10G69/00 Primary

  Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process (C10G67/00 takes precedence) · CPC title

• C10G50/00

  Production of liquid hydrocarbon mixtures from lower carbon number hydrocarbons, e.g. by oligomerisation · CPC title

• C10G47/00

  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) · CPC title