Processes for producing petrochemical products that utilize fluid catalytic cracking of lesser and greater boiling point fractions with steam

Patent metadata

Field	Value
Publication number	US-11332680-B2
Application number	US-202017009073-A
Country	US
Kind code	B2
Filing date	Sep 1, 2020
Priority date	Sep 1, 2020
Publication date	May 17, 2022
Grant date	May 17, 2022

Abstract

According to one more embodiments, presently disclosed are processes for producing petrochemical products from a hydrocarbon material. The process may include separating the hydrocarbon material into at least a lesser boiling point fraction and a greater boiling point fraction, combining steam with the greater boiling point fraction upstream of the cracking of the greater boiling point fraction, cracking at least a portion of the greater boiling point fraction in the presence of a first catalyst to produce a first cracking reaction product, combining steam with the lesser boiling point fraction upstream of the cracking of the lesser boiling point fraction, cracking at least a portion of the lesser boiling point fraction in the presence of a second catalyst to produce a second cracking reaction product, and separating the petrochemical products from one or both of the first cracking reaction product or the second cracking reaction product.

First claim

What is claimed is:

1. A process for producing petrochemical products from a hydrocarbon material, the process comprising:
separating the hydrocarbon material into at least a lesser boiling point fraction and a greater boiling point fraction;
combining steam with the greater boiling point fraction upstream of a cracking of the greater boiling point fraction such that the steam:oil mass ratio is at least 0.5 such that the partial pressure of the greater boiling point fraction is reduced;
cracking at least a portion of the greater boiling point fraction in the presence of a first catalyst at a reaction temperature of from 500° C. to 700° C. to produce a first cracking reaction product;
combining steam with the lesser boiling point fraction upstream of a cracking of the lesser boiling point fraction such that the steam:oil mass ratio is from 0.2 to 0.8 such that the partial pressure of the lesser boiling point fraction is reduced;
cracking at least a portion of the lesser boiling point fraction in the presence of a second catalyst at a reaction temperature of from 500° C. to 700° C. to produce a second cracking reaction product; and
separating the petrochemical products from one or both of the first cracking reaction product or the second cracking reaction product,
wherein an amount of steam introduced to the greater boiling point fraction is greater than an amount of steam introduced to the lesser boiling point fraction.

2. The process of claim 1 , further comprising:
separating cycle oil from one or both of the first cracking reaction product or the second cracking reaction product, wherein at least 99 wt. % of the cycle oil has a boiling point of at least 215° C.; and
recycling the cycle oil by combining the cycle oil with one or more of the lesser boiling point fraction, the greater boiling point fraction, or the hydrocarbon material.

3. The process of claim 1 , wherein at least 90 wt. % of the hydrocarbon material is present in the combination of the greater boiling point fraction and the lesser boiling point fraction.

4. The process of claim 1 , wherein the difference between the 5 wt. % boiling point and the 95 wt. % boiling point of the hydrocarbon material is at least 100° C.

5. The process of claim 1 , wherein:
the first cracking reaction product and the second cracking reaction product are combined to form a combined reaction product; and
a cycle oil is separated from the combined reaction product.

6. The process of claim 1 , further comprising:
separating at least a portion of the first cracking reaction product from a spent first catalyst;
separating at least a portion of the second cracking reaction product from a spent second catalyst;
regenerating at least a portion of the spent first catalyst to produce a regenerated first catalyst; and
regenerating at least a portion of the spent second catalyst to produce a regenerated second catalyst.

7. The process of claim 1 , wherein the hydrocarbon material is crude oil.

8. The process of claim 1 , wherein at least 40 wt. % of the combination of the first cracking reaction product and the second cracking reaction product comprise ethylene, propene, butene, pentene, or combinations thereof.

9. The process of claim 1 , wherein one or both of the first catalyst or second catalyst are regenerated.

10. The process of claim 1 , wherein the cut point of the lesser boiling point fraction and the greater boiling point fraction is from 180° C. to 400° C.

11. A process for operating a hydrocarbon feed conversion system for producing a petrochemical product stream from a hydrocarbon feed stream, the process comprising:
introducing the hydrocarbon feed stream to a feed separator;
separating the hydrocarbon feed stream into at least a lesser boiling point fraction stream and a greater boiling point fraction stream in the feed separator;
combining steam with the greater boiling point fraction stream upstream of a cracking of the greater boiling point fraction stream such that the steam:oil mass ratio is at least 0.5 such that the partial pressure of the components of the greater boiling point fraction is reduced;
combining steam with the lesser boiling point fraction stream upstream of a cracking of the lesser boiling point fraction stream such that the steam:oil mass ratio is from 0.2 to 0.8 such that the partial pressure of the components of the lesser boiling point fraction is reduced;
passing the greater boiling point fraction stream to a first fluidized catalytic cracking unit;
passing the lesser boiling point fraction stream to a second fluidized catalytic cracking unit;
cracking at least a portion of the greater boiling point fraction stream in the first fluidized catalytic cracking unit in the presence of a first catalyst at a reaction temperature of from 500° C. to 700° C. to produce a first cracking reaction product stream;
cracking at least a portion of the lesser boiling point fraction stream in the second fluidized catalytic cracking unit in the presence of a second catalyst and at a reaction temperature of from 500° C. to 700° C. to produce a second cracking reaction product stream; and
separating the petrochemical product stream from one or both of the first cracking reaction product stream or the second cracking reaction product stream,
wherein an amount of steam introduced to the greater boiling point fraction stream is greater than an amount of steam introduced to the lesser boiling point fraction stream.

12. The process of claim 11 , further comprising:
separating cycle oil stream from one or both of the first cracking reaction product stream or the second cracking reaction product stream, wherein at least 99 wt. % of the cycle oil stream has a boiling point of at least 215° C.; and
recycling the cycle oil stream by combining the cycle oil stream with the lesser boiling point fraction stream, the greater boiling point fraction stream, or the hydrocarbon feed stream.

13. The process of claim 11 , wherein at least 90 wt. % of the hydrocarbon feed stream is present in the combination of the greater boiling point fraction stream and the lesser boiling point fraction stream.

14. The process of claim 11 , wherein the difference between the 5 wt. % boiling point and the 95 wt. % boiling point of the hydrocarbon feed stream is at least 100° C.

15. The process of claim 11 , wherein:
the first cracking reaction product stream and the second cracking reaction product stream are combined to form a combined reaction product stream; and
a cycle oil stream is separated from the combined reaction product stream.

16. The process of claim 11 , further comprising:
separating at least a portion of the first cracking reaction product stream from a spent first catalyst;
separating at least a portion of the second cracking reaction product stream from a spent second catalyst;
regenerating at least a portion of the spent first catalyst to produce a regenerated first catalyst; and
regenerating at least a portion of the spent second catalyst to produce a regenerated second catalyst.

17. The process of claim 11 , wherein the hydrocarbon feed stream is crude oil.

18. The process of claim 11 , wherein at least 40 wt. % of the combination of the first cracking reaction product stream and the second cracking reaction product stream comprise ethylene, propene, butene, pentene, or combinations thereof.

19. The process of claim 11 , wherein one or both of the first catalyst or second catalyst are regenerated.

20. The process of claim 11 , wherein

Assignees

• Saudi Arabian Oil Co

Inventors

• Al-Ghrami Musaed Salem
• Akah Aaron Chi
• Bourane Abdennour

Classifications

• C10G2300/807

  Steam · CPC title

• C10G2300/4006

  Temperature · CPC title

• C10G2400/22

  Higher olefins · CPC title

• C10G2400/10

  Lubricating oil · CPC title

• C10G2400/20

  C2-C4 olefins · CPC title