Integrated process for converting crude oil to high value petrochemicals

Patent metadata

Field	Value
Publication number	US-11840672-B2
Application number	US-202318152941-A
Country	US
Kind code	B2
Filing date	Jan 11, 2023
Priority date	Jan 20, 2022
Publication date	Dec 12, 2023
Grant date	Dec 12, 2023

Abstract

The present invention relates to a process and system for complete conversion of crude oils by integrating Desalter unit, Atmospheric and vacuum column, high severity FCC process, Naphtha cracking process, residue slurry hydrocracking process, Delayed coking process, Selective mild hydrocracking aromatic production unit, Dehydrogenation units, Aromatic/olefin recovery section, gasifier unit along with syngas to olefins conversion section.

First claim

We claim:

1. A process for converting a crude oil to high value petrochemicals products, the process comprising:
i. charging the crude oil to a Desalter unit to obtain a desalted crude oil;
ii. fractionating the desalted crude oil in a primary fractionation section to obtain straight run fractions, wherein the straight run fractions comprise an upper Light cut having a boiling point below 350° C., a Middle cut having a boiling point in a range of 350-560° C. and a Lower heavy cut having a boiling point above 560° C.;
iii. routing the Lower heavy cut to a first Resid upgradation unit to obtain Fuel gas (FG) and LPG, Naphtha having a boiling point in a range of C 5 to 140° C., Light Gasoil (LGO) having a boiling point in a range of 140-370° C., Heavy Gasoil (HGO) having a boiling point in a range of 370-560° C. and unconverted Pitch having a boiling point above 560° C. by Residue Slurry Hydrocracking;
iv. routing the Middle cut from Primary fractionation section HGO from the first Resid upgradation unit and Heavy Coker Gas oil (HCGO) from a second Resid upgradation unit to a Hydrotreater Unit to obtain a combined Hydrotreated Gasoil stream;
v. routing the combined Hydrotreated Gasoil stream to a High severity Fluid Catalytic Cracking Unit (FCCU), to obtain FG, LPG, Naphtha having a boiling point in a range of C 5 to 210° C., Light Cycle Oil (LCO) having a boiling point in a range of 210 to 340° C., and Clarified oil (CLO) with a boiling point above 340° C.;
vi. routing the unconverted Pitch from the first Resid upgradation unit and CLO from the FCCU to the second Resid upgradation unit for Delayed Coking reactions to obtain FG, LPG, Coker Naphtha with a boiling point in a range of C 5 to 140° C., Light Coker Gas oil (LCGO) having a boiling point in a range of 140 to 370° C., Heavy Coker Gas oil (HCGO) having a boiling point in a range of 370 to 540° C. and Coke;
vii. withdrawing a part of the Coke as high value Coke product and routing the remaining Coke to a Coke Gasifier unit where it is converted to syngas, and syngas is converted to olefins using Syngas to Methanol (STM) and Methanol to Olefins (MTO) processes;
viii. splitting the LCGO stream from the second Resid upgradation unit into two parts on a mass ratio without altering boiling range (140-370° C.) and routing a first part along with the Light Cycle Oil from the high severity FCC unit and Light Cycle Oil having a boiling point in a range of 210 to 340° C. recycled from a Catalytic Naphtha Cracker unit, to a Selective Mild Hydrocracking unit (SMHC) to obtain Fuel Gas, LPG, a Light cut having a boiling point in a range of C 5 to 90° C., a Middle cut having a boiling point in a range of 90 to 180° C. and a Bottom cut having a boiling point above 180° C.;
ix. routing the upper Light cut having the boiling point below 350° C. from Primary fractionation section, the Naphtha having the boiling point in the range of C 5 to 140° C. from the first and the second Resid upgradation units, the Light cut having the boiling point in the range of C 5 to 90° C. from the SMHC unit, the LGO from the first Resid upgradation unit, the Naphtha having the boiling point in the range of C 5 to 210° C. from the FCCU and a second part of the LCGO stream from the second Resid upgradation unit to a Catalytic Naphtha cracker unit to obtain FG, LPG and Gasoline having a boiling point in a range of C 5 to 210° C., Light Cycle Oil having a boiling point in a range of 210 to 340° C. and Clarified oil (CLO) having a boiling point above 340° C.;
x. routing the FG and LPG from the first Resid upgradation unit, the High severity Fluid Catalytic Cracking Unit (FCCU), the second Resid upgradation unit, the Selective Mild Hydrocracking unit, the Catalytic Naphtha cracker unit, and a Methanol to Olefin conversion unit to Olefin recovery section having a C 2 splitter, a Propylene Recovery Unit (PRU) and a C 4 splitter, to obtain ethane, ethylene, propylene, butylenes and C 3 /C 4 paraffins;
xi. routing the C 3 paraffins stream to a propane dehydrogenation unit to obtain propylene;
xii. routing the C 4 paraffins back to Catalytic Naphtha cracker unit for complete conversion;
xiii. routing the Middle cut having the boiling point in the range of 90 to 180° C. from the Selective mild hydrocracking unit and the gasoline having the boiling point in the range of C 5 to 210° C. from the Catalytic naphtha cracker unit to an Aromatic recovery unit to obtain an extract stream containing Benzene, Toluene, Xylene and a raffinate stream containing paraffins;
xiv. routing the raffinate stream containing paraffins to the Catalytic Naphtha cracker unit as a recycle stream.

2. The process as claimed in claim 1 , wherein the desalted crude oil is fractionated in an atmospheric distillation unit, a vacuum distillation unit or a combination thereof.

3. The process as claimed in claim 1 , wherein the Primary fractionation section comprises an Atmospheric distillation unit operating at a pressure in a range of 1-2 Kg/cm 2 (g) and at a top temperature in a range of 150 to 250° C.; and a Vacuum distillation unit operating at a pressure in a range of 0.01 to 0.05 Kg/cm 2 (g).

4. The process as claimed in claim 1 , wherein the processing of the Light Coker Gas Oil from the second resid upgradation unit, the light cycle oil from the Catalytic Naphtha cracker unit and the Light Cycle Oil from the high severity FCC unit using Selective Mild Hydrocracking increases yield of aromatics and light olefins.

5. The process as claimed in claim 1 , wherein the mass ratio at which the LCGO stream from the second resid upgradation unit is split, is in a range of 10:90 to 90:10 for routing to the SMHC and the Catalytic Naphtha Cracker Units.

6. The process as claimed in claim 1 , wherein the upper light cut with the boiling point below 350° C. from the primary fractionation section, the Naphtha from the first and second Resid upgradation units, and FCC unit is optionally routed to a Thermal Naphtha cracker unit to generate lighter olefins, pyrolyzed gasoline, and ethylene tar (Pyrolytic Fuel oil) via a Naphtha hydrotreater unit to remove Sulfur and Nitrogen impurities.

7. The process as claimed in claim 1 , wherein the upper light cut with the boiling point below 350° C. from the primary fractionation section comprises Straight Run Naphtha, Kerosene, Light Gas Oil, Heavy Gas Oil and the middle cut comprises Vacuum diesel and Vacuum Gas Oil (VGO) and the Lower heavy cut comprises Vacuum Residue (VR).

8. The process as claimed in claim 1 , wherein the high value coke is a graphite grade coke with a sponge structure and a sulfur concentration in a range of 1-3 wt %.

9. The process as claimed in claim 1 , wherein the first Resid Upgradation Unit is a Residue Hydrocracking Unit, wherein a catalyst in the first Resid Upgradation Unit comprises an oil soluble liquid catalyst, and wherein the oil soluble catalyst comprises 1-5 wt % of Ni and 95-99 wt % of Mo.

10. The process as claimed in claim 6 , wherein the Naphtha Hydrotreater Unit is operated at a temperature in a range of 300-360° C. and at a pressure in a range of 10-20 bar.

11. The process as claimed in claim 1 , wherein the selective mild hydrocracking unit has two reactors for hydrotreating and for selective mild hydrocracking.

12. The process as claimed in claim 1 , wherein the Second Resid upgradation unit is a Delayed Coker Unit having coke drums, wherein the coke drums are operated at a temperature in a range of 470 to 520° C. and at an operating pressure ranging from 0.5 to 5 Kg/cm 2 (g) and a residence time in a range of 10 to 32 hours.

13. The process as claimed in claim 1 , wherein the High severity FCC unit

Assignees

• Indian Oil Corp Ltd

Inventors

• Pradeep Ponoly Ramachandran
• Siddiqui Shahil
• Nath Vineeth Venu
• Dave Darshankumar Manubhai
• Sarkar Mainak
• Das Satyen Kumar
• Sau Madhusudan
• RAMAKUMAR Sankara Sri Venkata

Classifications

• C10G67/16 Primary

  plural parallel stages only · CPC title

• C10G67/02

  plural serial stages only · CPC title

• C10G69/14

  plural parallel stages only · CPC title

• C10G2300/1033

  Oil well production fluids · CPC title

• C10G2300/301

  Boiling range · CPC title