Saudi Arabian Oil Company

King Fahd University of Petroleum and Minerals

Aaron Chi Akah

Musaed Salem Al-Ghrami

Qi Xu

Zhonglin Zhang

Mansour Ali Al-Herz

Ali Al Jawad

Lianhui Ding

Abdennour Bourane

Mansour Ali Al Herz

Abdullah Mohammed Aitani

Veera Venkata Ramakrishna Tammana

Wei Xu

Mohammed Abdul Bari Siddiqui

Ziyauddin S Qureshi

Essa Alnaimi

Bander Nasser Al Ghamdi

Anas Saleh Aqeeli

Bander A Al Ghamdi

Raed H Abudawoud

Siddiqui M Abdulbari

Musead Salem Al-Ghrami

Luis A Rojas Cordova

Ziyauddin R Qureshi

Enas Saleh Altarooti

Dominic Jude Anthony Kearney

Light olefins may be produced from a hydrocarbon feed by a method that includes separating the hydrocarbon feed into at least a light gas fraction stream comprising C-Calkanes, a light fraction stream comprising Calkanes, and a heavy fraction stream. The temperature cut between the light fraction stream and the heavy fraction stream may be at 280° C. to 320° C. The method may further include steam cracking at least a portion of the light gas fraction stream to produce a steam cracked effluent stream and catalytically cracking at least a portion of the light fraction stream and the heavy fraction stream in a steam enhanced catalytic cracker (SECC) to produce a catalytically cracked effluent stream. The steam cracked effluent stream and the catalytically cracked effluent stream may be sent to a product separator to produce the light olefins.

Integrated process for conversion of whole crude to light olefins

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 Chydrocarbon stream and a heavy Chydrocarbon stream; steam enhanced catalytically cracking the light Chydrocarbon stream; steam enhanced catalytically cracking the heavy Chydrocarbon 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.

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

A process for upgrading a hydrocarbon feed comprises contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both, where the cracking catalyst composition comprises a cracking additive comprising metal species impregnated on a ZSM-5 zeolite, where the metal species comprises a metal selected from the group consisting of chromium, vanadium, iron, platinum, molybdenum, cerium, and nickel.

Modified ZSM-5 for steam enhanced catalytic cracking of crude oil to light olefins and aromatics

An integrated process for upgrading a hydrocarbon oil feed stream utilizing a delayed coker and steam enhanced catalytic cracker includes solvent deasphalting the hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons, the heavy residual hydrocarbons including at least asphaltenes; delayed coking the heavy residual hydrocarbons to form petroleum coke and a delayed coker product stream; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a light Chydrocarbon stream, and a heavy Chydrocarbon stream; steam enhanced catalytically cracking the light Chydrocarbon stream to form a light steam enhanced catalytically cracked product stream including olefins, benzene, toluene, xylene, naphtha, or combinations thereof; and steam enhanced catalytically cracking the heavy Chydrocarbon stream to form a heavy steam enhanced catalytically cracked product including olefins, benzene, toluene, xylene, naphtha, or combinations thereof.

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

An integrated process for upgrading a hydrocarbon oil feed stream includes solvent deasphalting the hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons, delayed coking the heavy residual hydrocarbons to form petroleum coke and a delayed coker product stream; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a C-Chydrocarbon stream, a light Chydrocarbon stream, and a heavy Chydrocarbon stream; dehydrogenating the C-Chydrocarbon stream to form propylene and butylene; steam enhanced catalytically cracking the light Chydrocarbon stream to form a light steam enhanced catalytically cracked product stream including olefins, benzene, toluene, xylene, naphtha, or combinations thereof; and steam enhanced catalytically cracking the heavy Chydrocarbon stream to form a heavy steam enhanced catalytically cracked product including olefins, benzene, toluene, xylene, naphtha, or combinations thereof.

A process for the conversion of a petroleum feed to light olefins may comprise pretreating the petroleum feed to form one or more pretreated petroleum feeds and fractionating the one or more pretreated petroleum feeds to form a methane stream, an ethane stream, a C-Cstream, a light liquid fraction, and a heavy liquid fraction. The process may further comprise methane cracking the methane stream to form hydrogen, steam cracking the ethane stream to form a steam cracking product; dehydrogenating the C-Cstream to form a dehydrogenated stream; and steam enhanced catalytic cracking (SECC) the light liquid fraction and the heavy liquid fraction to form an SECC product.

Process for the conversion of petroleum to light olefins utilizing a pretreatment complex and steam enhanced catalytic cracker

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 C-Chydrocarbon stream, a light Chydrocarbon stream, and a heavy Chydrocarbon stream; dehydrogenating the C-Chydrocarbon stream to form propylene and butylene; steam enhanced catalytically cracking the light Chydrocarbon stream; steam enhanced catalytically cracking the heavy Chydrocarbon 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.

An integrated process for upgrading a hydrocarbon oil feed stream includes solvent deasphalting the hydrocarbon oil stream; processing the heavy residual hydrocarbons in a gasification unit to form syngas and gasification residue; hydrotreating the deasphalted oil stream to form a C-Chydrocarbon stream, a light Chydrocarbon stream, and a heavy Chydrocarbon stream; dehydrogenating the C-Chydrocarbon stream to form propylene and butylene; steam enhanced catalytically cracking the light Chydrocarbon stream; steam enhanced catalytically cracking the heavy Chydrocarbon 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.

Methods for processing a hydrocarbon oil feed stream utilizing a gasification unit, dehydrogenation unit, steam enhanced catalytic cracker, and an aromatics complex

In accordance with one or more embodiments herein, an integrated process for upgrading a hydrocarbon oil feed stream utilizing a gasification unit, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; processing the heavy residual hydrocarbons in a gasification unit to form syngas and gasification residue; hydrotreating the deasphalted oil stream to form a light Chydrocarbon stream and a heavy Chydrocarbon stream; steam enhanced catalytically cracking the light Chydrocarbon stream; steam enhanced catalytically cracking the heavy Chydrocarbon 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.

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

A method of processing a hydrocarbon feed may comprise fractionating the hydrocarbon feed into a light stream, a middle stream, a heavy stream, and a residue stream; hydrotreating the residue stream to form a hydrotreated residue stream; and feeding the light stream, middle stream, heavy stream, and the hydrotreated residue stream to a single Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a product stream comprising light olefins. The light stream and the hydrotreated residue streams may be exposed to more severe FCC cracking conditions than the middle stream and the middle stream may be exposed to more severe FCC cracking conditions than the heavy stream. The FCC reaction zone may be operated in a down-flow configuration and operated under high severity conditions.

Multi-zone catalytic cracking of crude oils

A method of processing a hydrocarbon feed may comprise fractionating the hydrocarbon feed into a light stream, a middle stream and a heavy stream; hydrotreating the heavy stream to form a hydrotreated heavy stream; feeding the light stream to a first Fluid Catalytic Cracking (FCC) reaction zone; feeding the middle stream to a second FCC reaction zone; and feeding the hydrotreated heavy stream to a third FCC reaction zone, thereby producing a heavy product stream comprising light olefins; and feeding one or more of the product streams to one or more fractionators, thereby producing one or more finished product streams and one or more recycle streams comprising one or more of light cycle oil (LCO), heavy cycle oil (HCO), and slurry oil; and hydrotreating one or more of the recycle streams to form the hydrotreated heavy stream.

A process for converting a hydrocarbon feed may comprise contacting a hydrocarbon feed with steam in the presence of a cracking catalyst under steam enhanced catalytic cracking conditions. The contacting the hydrocarbon feed with the steam in the presence of the cracking catalyst may cause at least a portion of the hydrocarbon feed to undergo steam catalytic cracking reactions to produce a cracked effluent comprising Cto Colefins, Cto Caromatic compounds, or both. The cracking catalyst may be a nanoparticle comprising: a core and a shell. The core may comprise one or more ZSM-5 zeolite particles and have an outer surface. The shell may comprise a plurality of fibers extending radially outward from the outer surface of the core. The plurality of fibers may comprise silica.

Processes for direct conversion of crude oil to light olefins and light aromatics through steam enhanced catalytic cracking over a core shell cracking catalyst

A process for converting crude oil to light olefins, aromatics, or both, includes contacting a crude oil with an FCC catalyst composition in a catalytic cracking system at a temperature of greater than or equal to 580° C., a weight ratio of the FCC catalyst to the crude oil of from 2:1 to 10:1, and a residence time of from 0.1 seconds to 60 seconds. Contacting causes at least a portion of hydrocarbons in the crude oil to undergo cracking reactions to produce a cracked effluent comprising at least olefins. The FCC catalyst composition for producing olefins and aromatics from crude oil includes ultrastable Y-type zeolite impregnated with lanthanum, ZSM-5 zeolite impregnated with phosphorous, an alumina binder, colloidal silica, and a matrix material comprising Kaolin clay.

Process and catalyst formulation for cracking crude oil to produce light olefins and aromatics

An integrated process and associated system for conversion of crude oil to value added petrochemicals. The process includes separating crude oil into light and heavy crude fractions and processing the heavy fraction in a solvent deasphalting unit and a delayed coker unit, and then providing the light fraction and selected effluents of the solvent deasphalting unit and the delayed coker unit to a hydrotreater. The process further includes separating the effluent of the hydrotreater to generate a Cfraction passed to a methane cracker, a Cfraction passed to an ethane steam cracker, a C-Cfraction passed to a dehydrogenation reactor, a hydrotreated light fraction passed to an aromatization unit, and a hydrotreated heavy fraction passed to a steam enhanced catalytic cracking unit. The process further includes separating effluents of the various unit operations into product streams including a BTX stream and a light olefin stream.

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Dhahran, Saudi Arabia

Aaron Chi Akah