Saudi Arabian Oil Company

King Fahd University of Petroleum and Minerals

Boreskov Institute of Catalysis

King Abdullah University of Science and Technology

Suadi Arabian Oil Company

Abdennour Bourane

Omer Refa Koseoglu

Ibrahim A Abba

Raheel Shafi

Abdul Rahman Zafer Akhras

Essam Sayed

Lianhui Ding

Stephane Kressmann

Musaed Salem Al-Ghrami

Kareemuddin Mahaboob Shaik

Alberto Lozano Ballesteros

Essam A Al-Sayed

Farhan M Al-Shahrani

Aqil Jamal

Aadesh Harale

Mourad Victor Younes

Wei Xu

Aaron Chi Akah

Mazin Tamimi

Esam Sayed

Shakeel Ahmed

Sameer Ali Al-Ghamdi

Mohammed Abdul Bari Siddiqui

Valentin Parmon

Mikhail Kerzhentsev

Svetlana Yashnik

Zinfer Ismagilov

Christopher F Dean

Julio Hasselmeyer

Raed H Abudawoud

Manal Al-Eid

Ibrahim Al-Nutaifi

Saad Al-Bogami

Stephan Ralf Vogel

Md Ashraful Islam

Emad Al-Shafi

Mohammed Ibrahim Katheeri

Adnan Al-Hajji

Ola S Ali

Ali Al Jawad

Mansour Ali Al Herz

Isidoro Morales Osorio

Ahmad Khowaiter

Marcus J Killingworth

Jorge Gascon Sabate

Jullian Vittenet

Mohammed Alabdullah

Gopal Juttu

Shatha Ali Alabbad

Khalid Ali Almajnouni

Duhaiman U Al-Yami

Alberto Rodriguez-Gomez

Abdulelah Alghadeer

Juttu Gopal

Furqan Al Jumah

Emad Al-shafi

Abrahim A Abba

Svetlana Yahnik

Farhan Al-Shahrani

Processes for producing products from crude oil include separating the crude oil into at least a lesser boiling point fraction and a greater boiling point fraction and passing the fractions to a reactor system that includes a riser section and a downer section. An outer boundary of the downer section is defined by a first wall in a plane perpendicular to a central axis, and outer boundaries of the riser section are defined by the first wall and a second wall in the plane perpendicular to the central axis. In an alternate arrangement, an outer boundary of the riser section is defined by a first wall in a plane perpendicular to a central axis, and outer boundaries of the downer section are defined by the first wall and a second wall in the plane perpendicular to the central axis. The process includes cracking the lesser boiling point fraction in the riser section in the presence of a catalyst and cracking the greater boiling point fraction in the downer reactor in the presence of the catalyst. The process includes passing the catalyst from the riser to the downer, from the downer to a regenerator, and from the regenerator to the riser.

Processes for producing petrochemical products from crude oil

A process for upgrading a hydrocarbon feed, such as crude oil or other heavy oils, may include hydrotreating a hydrocarbon feed in a hydrotreating unit to produce a hydrotreated effluent that includes asphaltenes, coke precursors, or both. The process further includes hydrocracking the hydrotreated effluent in a hydrocracking unit to produce a hydrocracked effluent, adsorbing at least a portion of the asphaltenes, coke precursors, or both, from the hydrotreated effluent, the hydrocracked effluent, or both, separating the hydrocracked effluent into at least an upgraded lesser-boiling effluent and a greater-boiling effluent in a hydrocracked effluent separation system, and steam cracking the upgraded lesser-boiling effluent to produce olefins, aromatic compounds, or combinations of these. The process may further include recycling the greater boiling effluent back to the hydrotreating unit and hydrocracking a middle distillate effluent from the hydrocracked effluent separation system. Systems for conducting the processes are also disclosed.

Systems and processes for upgrading and converting crude oil to petrochemicals through steam cracking

A processing facility is provided. The processing facility includes an asphaltenes and metals (AM) removal system configured to process a feed stream to produce a power generation stream, a hydroprocessing feed stream, and an asphaltenes stream. A power generation system is fed by the power generation feed stream. A hydroprocessing system is configured to process the hydroprocessing feed stream to form a gas stream and a liquid stream. A hydrogen production system is configured to produce hydrogen, carbon monoxide and carbon dioxide from the gas feed stream. A carbon dioxide conversion system is configured to produce synthetic hydrocarbons from the carbon dioxide, and a cracking system is configured to process the liquid feed stream.

Integrated production of hydrogen, petrochemicals, and power

A hydrocarbon feed stream may be processed by a method that may include catalytically cracking a hydrocarbon feed stream in a counter-current reactor to produce a first effluent stream, and processing a portion or all of the first effluent stream by at least one or more separations. The at least one or more separations may form at least a second effluent stream including at least 95 wt. % C-Chydrocarbons, and a third effluent stream including at least 95 wt. % of ethane, propane, or a combination thereof. In some embodiments, the method may further include catalytically cracking a portion or all of the second effluent stream in a second reactor to form a second reactor effluent stream, combining a portion of all of the second reactor effluent stream with the first effluent stream, steam cracking a portion or all of the third effluent stream to form a steam cracked effluent stream, and combining a portion or all of the steam cracked effluent stream with the first effluent. In other embodiments, the method may further include passing a portion or all of the second effluent stream to the counter-current reactor, steam cracking a portion or all of the third effluent stream to form a steam cracked effluent stream, and combining a portion or all of the steam cracked effluent stream with the first effluent stream.

Methods for processing hydrocarbon feed streams

Systems and processes are disclosed for producing petrochemical products, such as ethylene, propene and other olefins from crude oil in high severity fluid catalytic cracking (HSFCC) units. Processes include separating a crude oil into a light fraction and a heavy fraction, cracking the light fraction and heavy fraction in separation separate cracking reaction zones, and regenerating the cracking catalysts in a two-zone having a first regeneration zone for the first catalyst (heavy fraction) and a second regeneration zone for the second catalyst (light fraction) separate from the first regeneration zone. Flue gas from the first catalyst regeneration zone is passed to the second regeneration zone to provide additional heat to raise the temperature of the second catalyst of the light fraction side. The disclosed systems and processes enable different catalysts and operating conditions to be utilized for the light fraction and the heavy fraction of a crude oil feed.

High severity fluidized catalytic cracking systems and processes for producing olefins from petroleum feeds

Petrochemical products may be produced from a hydrocarbon material by a process that may include separating the hydrocarbon material into at least a lesser boiling point fraction and a greater boiling point fraction, cracking the lesser boiling point fraction in a first reactor in the presence of a catalyst at a reaction temperature of from 500&#xb0; C. to 700&#xb0; C. to produce a first cracking reaction product, and cracking the greater boiling point fraction in a second reactor in the presence of the catalyst at a reaction temperature of from 500&#xb0; C. to 700&#xb0; C. to produce a second cracking reaction product. The hydrocarbon material may be crude oil. The first reactor may be a riser, and the second reactor may be a downer. The catalyst may be passed from the first reactor to the second reactor, from the second reactor to a regenerator, and from the regenerator to the first reactor, such that the catalyst is circulated between the first reactor, second reactor, and regenerator. An amount of coke may be reduced on the catalyst in the regenerator.

Processes for producing petrochemical products that utilize a riser and a downer with shared catalyst regenerator

A processing facility is provided that includes a feedstock separation system configured to separate a feed stream into a lights stream and a heavies stream, a hydrogen production system configured to produce hydrogen and carbon dioxide from the lights stream, and a carbon dioxide conversion system configured to produce synthetic hydrocarbons or the carbon dioxide. The processing facility also includes a hydroprocessing system configured to process the heavies stream, and a hydroprocessor separation system configured to separate a hydroprocessing system effluent into a separator tops stream and a separator bottoms stream, wherein the separator bottoms stream is fed to the hydrogen production system.

Processing facility to produce hydrogen and petrochemicals

According to one or more embodiments, presently disclosed are processes for producing petrochemical products from a hydrocarbon material. The process may include separating the hydrocarbon material into at least a lesser boiling point fraction and a greater boiling point fraction, combining steam with the greater boiling point fraction upstream of the cracking of the lesser boiling point fraction, cracking at least a portion of the greater boiling point fraction in the presence of a first catalyst to produce a first cracking reaction product, cracking at least a portion of the lesser boiling point fraction in the presence of a second catalyst in an environment comprising less than 0.1 mol. % water to produce a second cracking reaction product, and separating the petrochemical products from one or both of the first cracking reaction product or the second cracking reaction product.

Processes for producing petrochemical products that utilize fluid catalytic cracking of a greater boiling point fraction with steam

Methods for operating a system having two downflow high-severity FCC units for producing products from a hydrocarbon feed includes introducing the hydrocarbon feed to a feed separator and separating it into a lesser boiling point fraction and a greater boiling point fraction. The greater boiling point fraction is passed to the first FCC unit and cracked in the presence of a first catalyst at 500&#xb0; C. to 700&#xb0; C. to produce a first cracking reaction product and a spent first catalyst. The lesser boiling point fraction is passed to the second FCC unit and cracked in the presence of a second catalyst at 500&#xb0; C. to 700&#xb0; C. to produce a second cracking reaction product and a spent second catalyst. At least a portion of the spent first catalyst or the spent second catalyst is passed back to the first FCC unit, the second FCC unit or both.

High-severity fluidized catalytic cracking systems and processes having partial catalyst recycle

According to one or more embodiments, presently disclosed are processes for producing petrochemical products from a hydrocarbon material. The process may include separating the hydrocarbon material into at least a lesser boiling point fraction and a greater boiling point fraction, cracking at least a portion of the greater boiling point fraction, cracking at least a portion of the lesser boiling point fraction, separating cycle oil from one or both of the first cracking reaction product or the second cracking reaction product, hydrotreating the cycle oil to form a hydrotreated cycle oil, and recycling the hydrotreated cycle oil.

Processes for producing petrochemical products that utilize hydrotreating of cycle oil

According to one more embodiments, presently disclosed are processes for producing petrochemical products from a hydrocarbon material. The process may include separating the hydrocarbon material into at least a lesser boiling point fraction and a greater boiling point fraction, combining steam with the greater boiling point fraction upstream of the cracking of the greater boiling point fraction, cracking at least a portion of the greater boiling point fraction in the presence of a first catalyst to produce a first cracking reaction product, combining steam with the lesser boiling point fraction upstream of the cracking of the lesser boiling point fraction, cracking at least a portion of the lesser boiling point fraction in the presence of a second catalyst to produce a second cracking reaction product, and separating the petrochemical products from one or both of the first cracking reaction product or the second cracking reaction product.

Processes for producing petrochemical products that utilize fluid catalytic cracking of lesser and greater boiling point fractions with steam

Systems and methods for direct crude oil upgrading to hydrogen and chemicals including separating an inlet hydrocarbon stream into a light fraction and a heavy fraction comprising diesel boiling point temperature range material; producing from the light fraction syngas comprising Hand CO; reacting the CO produced; producing from the heavy fraction and separating CO, polymer grade ethylene, polymer grade propylene, Ccompounds, cracking products, light cycle oils, and heavy cycle oils; collecting and purifying the COproduced from the heavy fraction; processing the Ccompounds to produce olefinic oligomerate and paraffinic raffinate; separating the cracking products; oligomerizing a light cut naphtha stream; hydrotreating an aromatic stream; hydrocracking the light cycle oils to produce a monoaromatics product stream; gasifying the heavy cycle oils; reacting the CO produced from gasifying the heavy cycle oils; collecting and purifying the CO; and processing and separating produced aromatic compounds into benzene and paraxylene.

Systems and processes for direct crude oil upgrading to hydrogen and chemicals

According to one more embodiments, petrochemical products may be produced from a hydrocarbon material by a process that may comprise separating the hydrocarbon material into at least a lesser boiling point fraction, a medium boiling point fraction, and a greater boiling point fraction. The process may further comprise cracking at least a portion of the lesser boiling point fraction and the medium boiling point fraction in a second reactor unit in the presence of a second catalyst at a reaction temperature of from 500&#xb0; C. to 700&#xb0; C. to produce a second cracking reaction product, wherein the lesser boiling point fraction enters the second reactor unit upstream of wherein the medium boiling point fraction enters the second reactor.

Processes for producing petrochemical products that utilize fluid catalytic cracking

Growing community of inventors

Ras Tanura, Saudi Arabia

Abdennour Bourane