Processes for high severity fluid catalytic cracking systems

Patent metadata

Field	Value
Publication number	US-2018244591-A1
Application number	US-201815967665-A
Country	US
Kind code	A1
Filing date	May 1, 2018
Priority date	Jun 23, 2016
Publication date	Aug 30, 2018
Grant date	—

Abstract

Embodiments of methods for converting gas condensate into a product stream comprising propylene comprise feeding gas condensate at a top region of a downflow high severity fluidized catalytic cracking reactor (HSFCC), where the gas condensate comprises: at least 50% by weight paraffins, and less than 0.1% by weight olefins. The method further comprises feeding catalyst to the top region of the downflow HSFCC reactor in an amount characterized by a catalyst to gas condensate weight ratio of about 5:1 to about 40:1, where the catalyst comprises nano-ZSM-5 zeolite catalyst having an average particle diameter from 0.01 to 0.2 μm, a Si/Al molar ratio from 20 to 40, and a surface area of at least 20 cm2/g. The method further comprises cracking the gas condensate in the presence of the catalyst at a reaction temperature of about 500° C. to about 700° C. to produce the product stream comprising propylene.

First claim

1 . A method of converting gas condensate into a product stream comprising propylene, the method comprising:
feeding gas condensate at a top region of a downflow high severity fluidized catalytic cracking reactor (HSFCC), the gas condensate comprising at least 50% by weight paraffins; feeding catalyst to the top region of the downflow HSFCC reactor in an amount characterized by a catalyst to gas condensate weight ratio of about 5:1 to about 40:1, where the catalyst comprises nano ZSM-5 zeolite catalyst having a Si/Al molar ratio from 20 to 40; and cracking the gas condensate in the presence of the catalyst at a reaction temperature of about 500° C. to about 700° C. to produce the product stream comprising propylene.

2 . The method of claim 1 further comprising adding steam to the top region of the downflow HSFCC reactor.

3 . The method of claim 1 , where the cracking occurs at a pressure of about 1 to 2 atm to produce the product stream comprising propylene.

4 . The method of claim 1 , where the gas condensate comprises less than 0.1% by weight olefins.

5 . The method of claim 1 , where the Si/Al atomic ratio is from 25 to 35.

6 . The method of claim 1 , where the product stream comprises at least a 20 wt % yield of propylene.

7 . The method of claim 1 , where the product stream comprises at least a 10 wt % yield of ethylene.

8 . The method of claim 1 , where the nano ZSM-5 catalyst is impregnated with phosphorus.

9 . The method of claim 1 , where the catalyst comprises 10 to 50 wt % of nano ZSM-5 catalyst.

10 . The method of claim 1 , where the catalyst comprises USY (Ultrastable Y zeolite).

11 . The method of claim 10 , where the USY catalyst is impregnated with lanthanum.

12 . The method of claim 10 , where the catalyst comprises 10 to 50 wt % of USY catalyst.

13 . The method of claim 1 , where the catalyst comprises one or more of alumina, clay, and silica.

14 . The method of claim 13 , where the clay comprises one or more components selected from kaolin, montmorillonite, halloysite, and bentonite.

15 . The method of claim 13 , where the catalyst comprises 30 to 70 wt % of clay.

16 . The method of claim 13 , where the catalyst comprises 2 to 20 wt % of alumina.

17 . The method of claim 13 , where the catalyst comprises 0.1 to 10 wt % of silica.

18 . The method of claim 1 , where the reaction temperature is about 550° C. to about 630° C.

19 . The method of claim 1 , where the gas condensate has a residence time in the downflow fluidized catalytic cracking reactor of 0.7 seconds to 10 seconds.

20 . The method of claim 1 , where the catalyst to gas condensate ratio is 5:1 to about 10:1.

21 . The method of claim 1 , where the catalyst comprises the nano ZSM-5 catalyst, USY catalyst, alumina, clay, and silica.

22 . The method of claim 1 , where the catalyst comprises from 10 to 50 wt % of nano ZSM-5 catalyst, 10 to 50 wt % of USY catalyst, 2 to 20 wt % of alumina, 30 to 70 wt % of clay, and 0.1 to 10 wt % of silica.

23 . The method of claim 1 , where the gas condensate comprises naphthenes and aromatics.

24 . The method of claim 23 , where the gas condensate comprises 65 wt % paraffins, 0 wt % olefins, 21 wt % naphthenes, and 15 wt % aromatics.

25 . The method of claim 1 , where the gas condensate has an initial boiling point of at least 0° C. and a final boiling point of at least 450° C. when measured according to a true boiling point analysis.

26 . The method of claim 1 , where the nano ZSM-5 zeolites has a surface area of at least 30 cm 2 /g.

27 . The method of claim 1 , where the gas condensate has a research octane number (RON) of 70 to 75 according to ASTM 2699 or ASTM 2700.

28 . The method of claim 1 , where the nano ZSM-5 zeolite catalyst has an average particle diameter from 0.01 to 0.2 μm.

29 . The method of claim 1 , where the nano ZSM-5 zeolite catalyst has a surface area of at least 20 cm 2 /g.

Assignees

• Saudi Arabian Oil Co

Inventors

• Al-Herz Mansour Ali
• Hould Nathan D
• Al-Asseel Ahmed
• Algozeeb Wala A
• Al-Ghrami Musaed

Classifications

• B01J29/088

  Y-type faujasite · CPC title

• B01J29/40 Primary

  of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively · CPC title

• B01J29/80

  Mixtures of different zeolites · CPC title

• C10G11/05 Primary

  Crystalline alumino-silicates, e.g. molecular sieves · CPC title

• C07C2529/40

  of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11 · CPC title