Process for production of hydrocarbon chemicals from crude oil

Patent metadata

Field	Value
Publication number	US-9550707-B2
Application number	US-201313856065-A
Country	US
Kind code	B2
Filing date	Apr 3, 2013
Priority date	Apr 4, 2012
Publication date	Jan 24, 2017
Grant date	Jan 24, 2017

Abstract

An integrated process comprising to convert crude oil, comprising: converting crude oil ( 10 ) in a feed preparation facility ( 800 ) by separating the crude oil to a gas fraction ( 101 ), liquid fraction ( 102 ), and first residuum fraction in an atmospheric distillation unit ( 100 ); separating the 1 st residuum to a vacuum gas oil fraction ( 202 ) and a second residuum ( 201 ) in a vacuum distillation unit ( 200 ); converting the vacuum gas oil fraction to a CU gas fraction ( 301,401 ), a CU liquid fraction ( 302 ), and an CU higher boiling fraction ( 303,402 ) in a cracking unit ( 300,400 ); and processing the second residuum fraction to DCU gas oil/lighter fraction ( 501 ) in a coking unit ( 500 ); and steam cracking at least one of the gas fraction ( 101 ), liquid fraction ( 102 ), CU gas fraction ( 301,401 ), and DCU gas oil/lighter fraction ( 501 ) to the hydrocarbon products ( 920 ).

First claim

The invention claimed is:

1. An integrated process to convert crude oil into fractions suitable for conversion to chemicals, comprising:
converting crude oil in a feed preparation facility by
separating the crude oil to a gas fraction, liquid fraction, and first residuum fraction in an atmospheric distillation unit;
separating the first residuum to a vacuum gas oil fraction and a second residuum fraction in a vacuum distillation unit;
converting the vacuum gas oil fraction to a CU gas fraction, a CU liquid fraction, and an CU higher boiling fraction in a cracking unit; and
processing the second residuum fraction to DCU gas oil/lighter fraction and coke in a coking unit; and

directing methane, C 3 paraffins, C 4 paraffins, and feedstock products from the feed preparation facility to a steam cracking facility and converting the feedstock products into hydrocarbon products by
steam cracking at least one of the gas fraction, liquid fraction, CU gas fraction, and DCU gas oil/lighter fraction to hydrocarbon products comprising at least one of ethylene, propylene, butylenes, butadiene, benzene, toluene, xylene, ethylbenzene, styrene, or a combination comprising at least one of the foregoing;

using hydrogen produced in the steam cracking facility in a unit of the feed preparation facility, wherein the hydrogen produced in the steam cracking facility supplies greater than 0 to as much as half the hydrogen supplied to the feed preparation facility; and
at least one of
utilizing a pyrolysis fuel oil produced in the steam cracking facility in units of the feed preparation facility, and
adding the pyrolysis fuel oil produced in the steam cracking facility to the second residuum fraction.

2. The process of claim 1 , wherein the cracking unit comprises a fluid catalytic cracking unit.

3. The process of claim 1 , wherein the cracking unit comprises a hydrocracking cracking unit.

4. The process of claim 1 , further comprising hydrotreating at least one of the liquid fraction, CU gas fraction, DCU gas oil/lighter fraction, to remove sulfur compounds.

5. The process of claim 1 , wherein the conversion of the crude oil to the feedstock products is at least 75%.

6. The process of claim 1 , further comprising reforming a portion of the liquid fraction in a reforming unit to form naphthalene, benzene, toluene, and xylene.

7. The process of claim 1 , further comprising hydrocracking a portion of the vacuum gas oil fraction to form an HCU gas fraction.

8. The process of claim 1 , further comprising blending light paraffins and olefins from the feed preparation facility are blended with olefins from a steam cracking unit upstream of a separation unit, wherein the separation unit is located downstream from the steam cracking unit of the steam cracking facility.

9. The process of claim 1 , wherein conversion of crude oil to the feedstock products is at least 80%.

10. An integrated process to convert crude oil into fractions suitable for conversion to chemicals, comprising:
converting crude oil in a feed preparation facility by
separating the crude oil to a gas fraction, liquid fraction, and first residuum fraction in an atmospheric distillation unit;
separating the first residuum to a vacuum gas oil fraction and a second residuum fraction in a vacuum distillation unit;
converting the vacuum gas oil fraction to a CU gas fraction, a CU liquid fraction, and a CU higher boiling fraction in a cracking unit; and
processing the second residuum fraction to DCU gas oil/lighter fraction and coke in a coking unit; and

converting feedstock products from the feed preparation facility into hydrocarbon products in a steam cracking facility by
steam cracking at least one of the gas fraction, liquid fraction, CU gas fraction, and DCU gas oil/lighter fraction to hydrocarbon products comprising at least one of ethylene, propylene, butylenes, butadiene, benzene, toluene, xylene, ethylbenzene, styrene, or a combination comprising at least one of the foregoing;

using hydrogen produced in the steam cracking facility in a unit of the feed preparation facility, wherein the hydrogen produced in the steam cracking facility supplies greater than 0 to as much as half the hydrogen supplied to the feed preparation facility; and
at least one of
utilizing a pyrolysis fuel oil produced in the steam cracking facility in units of the feed preparation facility, and
adding the pyrolysis fuel oil produced in the steam cracking facility to the second residuum fraction;

wherein conversion of crude oil to the feedstock products is at least 90%.

11. The process of claim 1 , wherein the feedstock products from the feed preparation facility comprise C 3 and C 4 paraffins.

12. The process of claim 1 , wherein conversion of crude oil to the feedstock products is at least 60%.

Assignees

• Saudi Basic Ind Corp

Inventors

• Schrod Heinrich Manfred
• Petzny Wilfried J

Classifications

• C10B57/045

  containing mineral oils, bitumen, tar or the like or mixtures thereof · CPC title

• C10G9/005

  Coking (in order to produce liquid products mainly) · CPC title

• C10G51/06

  plural parallel stages only · CPC title

• C10G51/00

  Treatment of hydrocarbon oils, in the absence of hydrogen, by two or more cracking processes only · CPC title

• C10G51/023

  only thermal cracking steps · CPC title