Methods for processing a hydrocarbon oil feed stream utilizing a delayed coker, steam enhanced catalytic cracker, and an aromatics complex

Patent metadata

Field	Value
Publication number	US-12378485-B2
Application number	US-202418442628-A
Country	US
Kind code	B2
Filing date	Feb 15, 2024
Priority date	Jul 15, 2022
Publication date	Aug 5, 2025
Grant date	Aug 5, 2025

Abstract

In accordance with one or more embodiments herein, an integrated process for upgrading a hydrocarbon oil feed stream utilizing a delayed coker, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; delayed coking the heavy residual hydrocarbons; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a light C 5+ hydrocarbon stream and a heavy C 5+ hydrocarbon stream; steam enhanced catalytically cracking the light C 5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C 5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

First claim

What is claimed is:

1. An integrated system for the conversion of hydrocarbon oil feed stocks utilizing a delayed coker, steam enhanced catalytic cracker, and an aromatics complex comprising a catalytic reformer and a transalkylation unit, comprising:
a solvent deasphalting unit configured to separate a hydrocarbon oil stream into at least a deasphalted oil stream and heavy residual hydrocarbons, the heavy residual hydrocarbons comprising at least asphaltenes;
a delayed coker fluidly connected to the solvent deasphalting unit and configured to de-coke the heavy residual hydrocarbons into at least a petroleum coke and a delayed coker product stream;
a hydrotreater fluidly connected to the solvent deasphalting unit and the delayed coker and configured to hydrotreat at least the deasphalted oil stream and the delayed coker product stream to form a light C 5+ hydrocarbon stream and a heavy C 5+ hydrocarbon stream;
a first steam enhanced catalytic cracker fluidly connected to the hydrotreater and configured to crack at least a portion of the light C 5+ hydrocarbon fraction to form a light steam enhanced catalytically cracked product; and
a second steam enhanced catalytic cracker fluidly connected to the hydrotreater, in parallel with the first steam enhanced catalytic cracker, and configured to crack at least a portion of the heavy C 5+ hydrocarbon fraction to form a heavy steam enhanced catalytically cracked product;
a product separator fluidly connected to the first and second steam enhanced catalytic crackers and configured to produce an olefin product stream, a naphtha product stream, and a BTX product stream;
the catalytic reformer fluidly connected immediately downstream of the product separator and configured to catalytically reform the naphtha product stream to produce a reformate stream comprising benzene, toluene, and xylenes; and
the transalkylation unit fluidly connected to the catalytic reformer and configured to upgrade the toluene in the reformate stream to produce additional benzene, xylenes, or both, and wherein
a ratio of gas hourly space velocity of steam to gas hourly space velocity of C 5+ hydrocarbon stream in the first and second steam enhanced catalytic crackers is from 0.1 to 1.1 times steam to C 5+ hydrocarbon stream.

2. The integrated system of claim 1 , wherein
the product separator is additionally configured to produce one or more product separator recycle streams;
the one or more product separator recycle streams comprise a methane recycle stream, a steam cracker recycle stream, a hydrotreater recycle stream, a delayed coker recycle stream, or combinations thereof;
the steam cracker recycle stream comprises C 2 -C 4 hydrocarbons;
the hydrotreater recycle stream comprises cracked naphtha, light cycle oil, or both; and
the delayed coker recycle stream comprises heavy cycle oil.

3. The integrated system of claim 2 , further comprising:
a methane cracker fluidly connected to the hydrotreater and product separator and configured to crack a C 1 hydrocarbon stream, the methane recycle stream, or both, to form hydrogen for recycling in the hydrotreater; and
a steam cracker fluidly connected to the hydrotreater and product separator and configured to crack a C 2 -C 4 hydrocarbon stream, the steam cracker recycle stream, or both, to form a steam cracked product stream comprising light olefins, naphtha, and BTX for separation in the product separator; and wherein,
the hydrotreater is additionally configured to form the C 1 hydrocarbon stream and the C 2 -C 4 hydrocarbon stream;
the hydrotreater is fluidly connected to the product separator and additionally configured to hydrotreat the hydrotreater recycle stream to produce additional C 1 hydrocarbon stream, C 2 -C 4 hydrocarbon stream, light C 5+ hydrocarbon stream, heavy C 5+ hydrocarbon stream, or combinations thereof;
the delayed coker is fluidly connected to the product separator and additionally configured to de-coke the delayed coker recycle stream to form additional petroleum coke and delayed coker product stream; and
the product separator is configured to send the methane recycle stream to the methane cracker, the steam cracker recycle stream to the steam cracker, the hydrotreater recycle stream to the hydrotreater, and the delayed coker recycle stream to the delayed coker.

4. The integrated system of claim 3 , wherein the aromatics complex further comprises one or more extractive distillation units fluidly connected to the catalytic reformer, the product separator, and the hydrotreater, and wherein the one or more extractive distillation units are configured to:
separate the benzene, toluene, and xylenes;
produce a C 1 -C 4 hydrocarbon recycle stream;
produce a C 9+ hydrocarbon stream;
send the C 1 -C 4 hydrocarbon recycle stream to the product separator to produce additional methane recycle stream, additional steam cracker recycle stream, or both; and
send the C 9+ hydrocarbon stream to the hydrotreater to produce additional C 1 hydrocarbon stream, C 2 -C 4 hydrocarbon stream, light C 5+ hydrocarbon stream, heavy C 5+ hydrocarbon stream, or combinations thereof.

5. The integrated system of claim 3 , further comprising a dehydrogenation unit fluidly connected to the hydrotreater and the final product separator, the dehydrogenation unit configured to dehydrogenate a C 3 -C 4 portion of the C 2 -C 4 hydrocarbon stream from the hydrotreater to form propylene and butylene, and wherein:
the steam cracker is configured to crack a C 2 portion of the C 2 -C 4 hydrocarbon stream from the hydrotreater.

6. The integrated system of claim 1 , further comprising a feed separator fluidly connected to the solvent deasphalting unit, the first steam enhanced catalytic cracker, the catalytic reformer, and the transalkylation unit and configured to separate the hydrocarbon oil stream into at least a heavy oil fraction stream, a feed middle distillate stream, and a feed naphtha stream and wherein,
the solvent desasphalting unit is additionally configured to separate the heavy oil fraction into at least the heavy residual hydrocarbons and the de-asphalted oil stream;
the first steam enhanced catalytic cracker is additionally configured to crack the feed middle distillate stream into the light steam enhanced catalytically cracked product;
the catalytic reformer is additionally configured to catalytically reform the feed naphtha stream to produce additional reformate stream; and
the transalkylation unit is additionally configured to upgrade the toluene in the additional reformate stream to produce additional benzene, xylenes, or both.

7. The integrated system of claim 1 , wherein:
the first steam enhanced catalytic cracker is additionally configured to form a olefin to naphtha ratio of from 2:1 to 7:1 olefins to naphtha; and
the second steam enhanced catalytic cracker is additionally configured to form a olefin to naphtha ratio of from 1.5:1 to 0.8:1 olefins to naphtha.

8. The integrated system of claim 1 , wherein the hydrocarbon oil stream comprises whole crude oil or crude oil fractions.

9. The integrated system of claim 4 , wherein:
the solvent deasphalting unit is operated at a temperature of from 60° C. to 90° C. and a pressure of from 0.1 MPa to 0.4 MPa;
the delayed coker is operated at a temperature of from 450° C. to 600° C. and a pressure of from 0.1 MPa to 0.4 MPa;
the hydrotreater is operated at a temperature of from 370° C. to 500° C. and a pressure of from 0.1 MPa to 0.2 MPa;
the first and second steam enhanced catalytic crackers are operated at a temperature of from 525° C. to 750° C. and a pressure of from 0.1 MPa to 0.2 MPa;
the methane cracker is operated at a temperature of from 850° C. to 1200°

Assignees

• Saudi Arabian Oil Co

Inventors

• Xu Qi
• Akah Aaron Chi
• Al-Ghrami Musaed Salem
• Zhang Zhonglin

Classifications

• C10G2400/30

  Aromatics · CPC title

• C10G2400/20

  C2-C4 olefins · CPC title

• C10G2300/42

  Hydrogen of special source or of special composition · CPC title

• C10G2300/4081

  Recycling aspects · CPC title

• C10G2300/4018

  Spatial velocity, e.g. LHSV, WHSV · CPC title