Processes for producing petrochemical products from crude oil

Patent metadata

Field	Value
Publication number	US-12227704-B2
Application number	US-202218052308-A
Country	US
Kind code	B2
Filing date	Nov 3, 2022
Priority date	Nov 3, 2022
Publication date	Feb 18, 2025
Grant date	Feb 18, 2025

Abstract

Processes for producing products from crude oil include separating the crude oil into at least a lesser boiling point fraction and a greater boiling point fraction and passing the fractions to a reactor system that includes a riser section and a downer section. An outer boundary of the downer section is defined by a first wall in a plane perpendicular to a central axis, and outer boundaries of the riser section are defined by the first wall and a second wall in the plane perpendicular to the central axis. In an alternate arrangement, an outer boundary of the riser section is defined by a first wall in a plane perpendicular to a central axis, and outer boundaries of the downer section are defined by the first wall and a second wall in the plane perpendicular to the central axis. The process includes cracking the lesser boiling point fraction in the riser section in the presence of a catalyst and cracking the greater boiling point fraction in the downer reactor in the presence of the catalyst. The process includes passing the catalyst from the riser to the downer, from the downer to a regenerator, and from the regenerator to the riser.

First claim

What is claimed is:

1. A process for producing petrochemical products from crude oil, the process comprising:
separating the crude oil into at least a lesser boiling point fraction and a greater boiling point fraction;
passing the lesser boiling point fraction and the greater boiling point fraction to a reactor system, the reactor system comprising a riser section and a downer section, wherein:
the reactor system comprises a first substantially prism-shaped wall arranged around a central axis, the central axis oriented in a substantially vertical direction;

the reactor system comprises a second substantially prism-shaped wall arranged around the central axis, a cross section of the second substantially prism-shaped wall surrounds the cross-section of the first substantially prism-shaped wall in a plane perpendicular to the central axis;
an outer boundary of the downer section is defined by the first substantially prism-shaped wall in the plane perpendicular to the central axis;
outer boundaries of the riser section are defined by the first substantially prism-shaped wall and the second substantially prism-shaped wall in the plane perpendicular to the central axis;

cracking the lesser boiling point fraction in the riser section in the presence of a catalyst to produce a first cracking reaction product, wherein the catalyst and the lesser boiling point fraction move co-currently and in a generally upwards direction through the riser section;
separating at least a portion of the first cracking reaction product from the catalyst such that a first cracking reaction product stream is passed out of the reactor system and the catalyst is passed to the downer section;
cracking the greater boiling point fraction in the downer reactor in the presence of the catalyst to produce a second cracking reaction product, wherein the catalyst and the greater boiling point fraction move co-currently in a generally downward direction through the downer section; and
passing the catalyst from the riser reactor to the downer reactor, from the downer reactor to a regenerator, and from the regenerator to the riser reactor, wherein an amount of coke on the catalyst is reduced in the regenerator.

2. The process of claim 1 , wherein the first substantially prism-shaped wall has a circular, oval, elliptical, or polygonal cross-sectional shape in a plane perpendicular to the central axis, and the second substantially prism-shaped wall has a circular, oval, elliptical, or polygonal cross-sectional shape in a plane perpendicular to the central axis.

3. The process of claim 1 , wherein the first substantially prism-shaped wall has a circular cross-sectional shape in a plane perpendicular to the central axis and the second substantially prism-shaped wall has a circular cross-sectional shape in a plane perpendicular to the central axis, wherein the first substantially prism-shaped wall is a first radial distance from the central axis, the second prism-shaped wall is a second radial distance from the central axis, and the second radial distance is greater than the first radial distance.

4. The process of claim 1 , wherein a cross section of the downer section, perpendicular to the central axis, is circular, and a cross section of the riser section, perpendicular to the central axis, is annular.

5. The process of claim 1 , wherein the reactor system further comprises a first separator and a second separator, wherein the first separator is in fluid communication with the riser section and the downer section, and wherein the second separator is in fluid communication with the downer section and the regenerator.

6. The process of claim 1 , wherein a reaction temperature in the riser section is from 620° C. to 680° C., and a reaction temperature in the downer section is from 580° C. to 640° C.

7. The process of claim 1 , wherein a residence time in the riser section is from 0.2 seconds to 5 seconds, and a residence time in the downer section is from 0.2 second to 2 seconds.

8. The process of claim 1 , wherein a catalyst to hydrocarbon ratio in the riser section and downer section is from 10:1 to 30:1.

9. The process of claim 1 , wherein a cut point of the lesser boiling point fraction and the greater boiling point fraction is from 250° C. to 400° C.

10. The process of claim 1 , wherein the first cracking reaction product, the second cracking reaction product, or both, comprise at least one of ethylene, propene, butene, or pentene.

11. The process of claim 1 , further comprising separating at least a portion of the second cracking reaction product from the catalyst such that a second cracking reaction product stream is passed out of the reactor system and the catalyst is passed to the regenerator.

Assignees

• Saudi Arabian Oil Co

Inventors

• Islam Md Ashraful
• Juttu Gopal
• Bourane Abdennour

Classifications

• C10G2400/22

  Higher olefins · CPC title

• C10G2400/20

  C2-C4 olefins · CPC title

• C10G2300/70

  Catalyst aspects · CPC title

• C10G2300/308

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

• C10G2300/1048

  Middle distillates · CPC title