Integrated hydrocracking process

• US 9,850,438 B2
• Filed: 12/23/2014
• Issued: 12/26/2017
• Est. Priority Date: 02/25/2014
• Status: Active Grant

• Current Assignee: SABIC Global Technologies BV (Government of Saudi Arabia), Saudi Basic Industries Corporation (Government of Saudi Arabia)
• Original Assignee: SABIC Global Technologies BV (Government of Saudi Arabia), Saudi Basic Industries Corporation (Government of Saudi Arabia)
• Inventors: Oprins, Arno Johannes Maria
• Primary Examiner(s): Boyer, Randy
• Assistant Examiner(s): Valencia, Juan
• Application Number:
  US15/121,096
• Publication Number:
  US 20170009154A1
• Time in Patent Office: 1,099 Days
• CPC Class Codes: C10B 57/045 containing mineral oils, bitumen, tar or the like or mixtures thereof
• CPC Class Codes: C10G 2400/20 C2-C4 olefins
• CPC Class Codes: C10G 2400/22 Higher olefins
• CPC Class Codes: C10G 2400/30 Aromatics
• CPC Class Codes: C10G 69/00 Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process C10G67/00 takes precedence
• CPC Class Codes: C10G 69/06 including at least one step of thermal cracking in the absence of hydrogen
• CPC Class Codes: C10G 9/00 Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
• CPC Class Codes: C10G 9/005 Coking (in order to produce liquid products mainly)
• CPC Class Codes: C10G 9/36 with heated gases or vapours
• CPC Class Codes: Y02P 20/129 Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines

Abstract

An integrated hydrocracking process for production of olefinic and aromatic petrochemicals from a hydrocarbon feedstock having crude oil. An object of the present invention is to provide an integrated hydrocracking process for the production of olefinic and aromatic petrochemicals from a hydrocarbon feedstock comprising crude oil in which the portion of crude oil converted to LPG is increased significantly.

Claims

1. An integrated hydrocracking process for production of olefinic and aromatic petrochemicals from a hydrocarbon feedstock comprising crude oil, the process comprising:

treating the hydrocarbon feedstock comprising crude oil and a coker liquid product in a first hydrocracking zone in the presence of hydrogen under conditions producing a first effluent having an increased hydrogen content;

separating the first effluent into a liquefied petroleum gas (LPG) comprising stream and a liquid phase stream;

separating said LPG comprising stream into one or more streams selected from the group consisting of a stream comprising hydrogen, a stream comprising methane, a steam comprising ethane, a stream comprising butanes, a stream comprising propane and a stream comprising C4-minus;

further processing one or more of the streams obtained in a steam cracker unit and at least one unit chosen from a butanes dehydrogenation unit, a propane dehydrogenation unit, a combined propane-butanes dehydrogenation unit, or a combination of units thereof to produce a mixed product stream(s);

feeding said mixed product stream(s) from said steam cracker unit and said at least one unit, chosen from said butanes dehydrogenation unit, said propane dehydrogenation unit, said combined propane-butanes dehydrogenation unit, or said combination of units thereof to a second separation section;

thermally cracking the liquid phase feed under effective conditions producing coke and a coker liquid product, wherein the coker liquid product is recycled to the first hydrocracking zone and wherein petroleum coke is recovered;

separating the mixed product stream(s).

3. The process according to claim 1, further comprising feeding at least one stream chosen from said stream comprising propane, said stream comprising butanes said stream comprising C4-minus, to at least one dehydrogenation unit chosen from said butanes dehydrogenation unit and said propane dehydrogenation unit, or a combination thereof.

4. The process according to claim 1, further comprising:

recovering olefins and aromatics from the separated mixed product stream.

5. The process according to claim 1, further comprising:

treating said liquid phase feed in a second hydrocracking zone in the presence of hydrogen under effective conditions producing a second effluent having an increased hydrogen content; and

recovering from the second effluent from said second hydrocracking zone a stream comprising a mixture of benzene, toluene, xylenes, and ethyl benzene (BTXE), a LPG comprising stream and a residual liquid stream.

6. The process according to claim 5, further comprising thermally cracking said residual liquid stream under effective conditions producing coke and the coker liquid product, wherein:

the coker liquid product is recycled to an inlet of the first hydrocracking and/or second hydrocracking zone, and wherein petroleum coke is recovered.

7. The process according to claim 5, further comprising combining the LPG comprising stream originating from said first hydrocracking zone with the LPG comprising stream originating from said second hydrocracking zone.

8. The process according to claim 1, further comprising recovering vapour products from the coker liquid product and combining the vapour products recovered with the LPG comprising stream(s).

9. The process according to claim 5, further comprising separating from the first effluent originating from said first hydrocracking zone and the effluent originating from said second hydrocracking zone residual liquid fractions and recycling said residual liquid fractions to inlet of the first hydrocracking and/or second hydrocracking zone.

10. The process according to claim 1, further comprising recovering methane from the separated mixed product stream(s) and recycling said methane to the steam cracker to be used as fuel for burners and/or heaters.

11. The process according to claim 5, further comprising recovering and purifying hydrogen from the separated mixed product stream(s) and recycling it to an inlet of the first and/or second hydrocracking zone.

12. The process according to claim 5, further comprising recovering pyrolysis fuel oil from the separated mixed product stream(s) and recycling said pyrolysis fuel oil to an inlet of said first and/or second hydrocracking zone.

13. The process according to claim 1, further comprising:

recovering an olefin from the separated mixed product stream.

14. The process according to claim 1, further comprising:

recovering aromatic from the separated mixed product stream.

15. The process according to claim 1, further comprising recovering vapour products from the coker liquid product.

16. The process according to claim 1, further comprising:

treating said liquid phase feed in a second hydrocracking zone in the presence of hydrogen under effective conditions producing a second effluent having an increased hydrogen content.

17. The process according to claim 1, further comprising:

treating said liquid phase feed in a second hydrocracking zone in the presence of hydrogen under effective conditions producing a second effluent having an increased hydrogen content; and

recovering from the second effluent from said second hydrocracking zone a LPG comprising stream.

18. The process according to claim 1, further comprising:

treating said liquid phase feed in a second hydrocracking zone in the presence of hydrogen under effective conditions producing a second effluent having an increased hydrogen content; and

recovering from the second effluent from said second hydrocracking zone a stream comprising a mixture of benzene, toluene, xylenes, and ethyl benzene (BTXE).

19. The process according to claim 1, further comprising:

treating said liquid phase feed in a second hydrocracking zone in the presence of hydrogen under effective conditions producing a second effluent having an increased hydrogen content; and

recovering from the second effluent from said second hydrocracking zone a residual liquid stream.

20. The process according to claim 1, further comprising recovering methane from the separated mixed product stream(s).

2. An integrated hydrocracking process for production of olefinic and aromatic petrochemicals from a hydrocarbon feedstock comprising crude oil, the process comprising:

treating the hydrocarbon feedstock comprising crude oil and a coker liquid product in a first hydrocracking zone in the presence of hydrogen under conditions producing a first effluent having an increased hydrogen content;

separating the first effluent into a liquefied petroleum gas (LPG) comprising stream and a liquid phase stream;

separating said LPG comprising stream into one or more streams selected from the group consisting of a stream comprising ethane and a stream comprising C2-minus;

further processing one or more of the streams obtained in a steam cracker unit and at least one unit chosen from a butanes dehydrogenation unit, a propane dehydrogenation unit, a combined propane-butanes dehydrogenation unit, or a combination of units thereof to produce at lease one mixed product stream;

feeding said at least one mixed product stream from said steam cracker unit and said at least one unit, chosen from said butanes dehydrogenation unit, said propane dehydrogenation unit, said combined propane-butanes dehydrogenation unit, or said combination of units thereof to a second separation section;

thermally cracking the liquid phase feed under effective conditions producing coke and a coker liquid product, wherein the coker liquid product is recycled to the first hydrocracking zone and wherein petroleum coke is recovered;

separating the at least one mixed product stream, and feeding at least one stream chosen from the group of said stream comprising ethane, and said stream comprising C2-minus to said steam cracker unit.