Saudi Arabian Oil Company

Ali Al Jawad

Qi Xu

Aaron Chi Akah

Musaed Salem Al-Ghrami

Mansour Ali Al-Herz

Abdennour Bourane

Zhonglin Zhang

Raed H Abudawoud

Lianhui Ding

Alberto Lozano Ballesteros

Mansour Ali Al Herz

Luis A Rojas Cordova

Enas Saleh Altarooti

Dominic Jude Anthony Kearney

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.

Embodiments of the present disclosure are directed to a method of processing a hydrocarbon feed includes fractionating the hydrocarbon feed into a light stream and a heavy stream, hydrotreating the heavy stream to form a hydrotreated heavy stream, combining the light stream and the hydrotreated heavy stream to form a upgraded feed stream, and feeding the upgraded feed stream to a single Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a product stream comprising light olefins. The light stream may comprise hydrocarbons boiling at less than 343° C. and the heavy stream may comprise hydrocarbons boiling at greater than 343° C. The FCC reaction zone may be operated in a down-flow configuration and the FCC may be operated under high severity conditions.

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 Fluid Catalytic Cracking (FCC) reaction zone. The light stream may comprise hydrocarbons boiling at less than 200° C. The middle stream may comprise hydrocarbons boiling at from 200° C. to 370° C. The heavy stream may comprise hydrocarbons boiling at greater than greater than 370° C. Each of the first and second FCC reaction zones may operate under more severe operating conditions than the third FCC reaction zone.

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; and feeding the light stream, middle stream, and the hydrotreated heavy stream to a single Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a product stream comprising light olefins. The light stream 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 hydrotreated heavy stream, within the same FCC reaction zone. The single FCC reaction zone may be operated in a down-flow configuration and under high severity conditions.

A method of processing a hydrocarbon feed may comprise fractionating the hydrocarbon feed into a light stream and a heavy stream, where the light stream includes hydrocarbons boiling at less than 370° C., and the heavy stream includes hydrocarbons boiling at greater than greater than 370° C., hydrotreating the heavy stream to form a hydrotreated heavy stream, feeding the light stream to a first Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a light product stream which includes light olefins, and feeding the hydrotreated heavy stream to a second Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a heavy product stream which includes light olefins, where the first FCC reaction zone operates under more severe operating conditions than the second FCC reaction zone.

According to one embodiment of the present disclosure, a method of processing a hydrocarbon feed includes fractionating the hydrocarbon feed into a light stream and a heavy stream; hydrotreating the heavy stream to form a hydrotreated heavy stream; feeding the light stream and the hydrotreated heavy stream to a single Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a product stream which includes light olefins. The light stream may be exposed to more severe FCC cracking conditions than the heavy stream, within the same FCC reaction zone. The single FCC reaction zone may be operated in a down-flow configuration and the FCC may be operated under high severity conditions. The light stream may include hydrocarbons boiling at less than 371° C. and the heavy stream may include hydrocarbons boiling at greater than 371° C.

According to one embodiment of the present disclosure, a method of processing a hydrocarbon feed may comprise fractionating the hydrocarbon feed into a light stream, a middle stream, and a residue stream, hydrotreating the residue stream to form a hydrotreated residue stream; and feeding the light stream, middle 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, within the same FCC reaction zone. The single FCC reaction zone may be operated in a down-flow configuration and the single FCC reaction zone may be operated under high severity conditions.

Embodiments of the present disclosure are directed to a method of processing a hydrocarbon feed includes fractionating the hydrocarbon feed into a light stream and a heavy stream, hydrotreating the heavy stream to form a hydrotreated heavy stream, combining the light stream and the hydrotreated heavy stream to form a upgraded feed stream, and feeding the upgraded feed stream to a single Fluid Catalytic Cracking (FCC) reaction zone, thereby producing a product stream comprising light olefins. The light stream may comprise hydrocarbons boiling at less than 540° C. and the heavy stream may comprise hydrocarbons boiling at greater than 540° C. The FCC reaction zone may be operated in a down-flow configuration and the FCC may be operated under high severity conditions.

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.

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Al-Qatif, Saudi Arabia

Ali Al Jawad