Process and system for conversion of crude oil to chemicals and fuel products integrating steam cracking and fluid catalytic cracking

Abstract

An integrated process converting crude oil to petrochemical products including olefins and aromatics, and fuel products, is disclosed. The process includes steam cracking and fluid catalytic cracking. Feed to the steam cracker include several naphtha fractions from hydroprocessing zones within the battery limits, and recycle streams from extraction zones within the battery limits.

1 . An integrated process for producing petrochemicals and fuel products from a crude oil feed comprising:
 separating from the crude oil feed in an atmospheric distillation zone at least a first ADU fraction comprising straight run naphtha; a second ADU fraction comprising at least a portion of middle distillates from the crude oil feed, and a third ADU fraction comprising atmospheric residue;   separating from the third ADU fraction in a vacuum distillation zone a first VDU fraction comprising vacuum gas oil;   processing in a distillate hydroprocessing zone at least a portion of the second ADU fraction to produce at least a first DHP fraction and a second DHP fraction, wherein the first DHP fraction comprises naphtha and the second DHP fraction is used for diesel fuel production;   processing in a fluid catalytic cracking zone the first VDU fraction to produce at least a first FCC fraction corresponding to light olefins that are recovered as petrochemicals, a second FCC fraction corresponding to FCC naphtha and a third FCC fraction corresponding to cycle oil;   processing in a mixed feed stream cracking zone the first ADU fraction and an aromatics extraction zone raffinate, to produce at least
 a mixed product stream comprising H2, methane, ethane, ethylene, mixed C3s and mixed C4s, 
 a pyrolysis gas stream, and 
 a pyrolysis oil stream; 
   recovering, from the mixed product stream, H2, methane, ethane, non-olefinic C3s and C4, and petrochemcials ethylene, propylene and butylenes,   passing recovered ethane and non-olefinic C3s to the mixed feed stream cracking zone, and passing non-olefinic C4s to the mixed feed stream cracking zone or to a separate processing zone for production of additional petrochemicals;   processing in a naphtha hydroprocessing zone pyrolysis gas from the mixed feed stream cracking zone to produce hydrotreated pyrolysis gas;   processing hydrotreated pyrolysis gas in an aromatics extraction zone to recover aromatic products and the aromatics extraction zone raffinate that is recycled to the mixed feed stream cracking zone.   
     
     
         2 . The process as in  claim 1 , wherein the first DHP fraction is passed to the mixed feed steam cracking zone. 
     
     
         3 . The process as in  claim 1 , wherein the first DHP fraction is passed to the mixed feed steam cracking zone through the atmospheric distillation zone, wherein the first DHP fraction passes to the mixed feed steam cracking zone with the first ADU fraction. 
     
     
         4 . The process as in any of  claims 1 - 3 , further comprising hydrotreating the second FCC fraction to produce hydrotreated FCC naphtha. 
     
     
         5 . The process as in  claim 4 , further comprising recovering C5s from the hydrotreated FCC naphtha and recycling the recovered C5s to the mixed feed stream cracking zone. 
     
     
         6 . The process as in  claim 4  or  5 , further comprising processing the hydrotreated FCC naphtha in the aromatics extraction complex for recovery of additional aromatic products and additional aromatics extraction zone raffinate that is recycled to the mixed feed stream cracking zone. 
     
     
         7 . The process as in any of  claims 1 - 6 , further comprising recovering C5s from the hydrotreated pyrolysis gas and passing the recovered C5s to the mixed feed stream cracking zone, the separate processing zone for production of additional petrochemicals, or both to the mixed feed stream cracking zone and the separate processing zone for production of additional petrochemicals. 
     
     
         8 . The process as  claim 7  wherein the recovered C5s are passed to the mixed feed stream cracking zone. 
     
     
         9 . The process as  claim 7  wherein the recovered C5s are passed to the separate processing zone for production of additional petrochemicals, wherein the separate processing zone converts mixture of butenes into mixed butanols. 
     
     
         10 . The process as in any of  claims 1 - 9 , further comprising processing in a gas oil hydroprocessing zone the first VDU fraction prior to processing in the fluid catalytic cracking zone, wherein the gas oil hydroprocessing zone produces a first GOHP fraction containing hydrotreated distillates and a second GOHP fraction containing hydrotreated gas oil, wherein the second GOHP fraction is passed to the fluid catalytic cracking zone. 
     
     
         11 . The process as in  claim 10 , wherein the hydrotreated distillates in the first GOHP fraction comprise naphtha that is routed to the mixed feed stream cracking zone and middle distillates used for fuel production. 
     
     
         12 . The process as in  claim 11 , wherein the naphtha from the first GOHP fraction is passed to the mixed feed steam cracking zone. 
     
     
         13 . The process as in  claim 11 , wherein the naphtha from the first GOHP fraction is passed to the mixed feed steam cracking zone through the atmospheric distillation zone, wherein the naphtha from the first GOHP fraction passes to the mixed feed steam cracking zone with the first fraction. 
     
     
         14 . The process as in  claim 10 , wherein the first GOHP fraction is passed to the distillate hydroprocessing zone. 
     
     
         15 . The process as in  claim 10 , further wherein the middle distillates in the second ADU fraction comprise heavy atmospheric gas oil that is processed in the gas oil hydroprocessing zone. 
     
     
         16 . The process as in  claim 10 , further wherein the middle distillates in the second ADU fraction comprise heavy atmospheric gas oil that is processed in the fluid catalytic cracking zone without hydroprocessing, and the first VDU fraction is hydroprocessed in the gas oil hydroprocessing zone. 
     
     
         17 . The process as in  claim 10 , further comprising passing at least a portion of the third FCC fraction in the distillate hydroprocessing zone. 
     
     
         18 . The process as in any of  claims 1 - 17 , wherein the step of separating from the crude oil feed in an atmospheric distillation zone further comprises recovering light petroleum gases, the process further comprising processing the light petroleum gases in a saturated gas plant to recover C3s and C4s that are routed to the mixed feed stream cracking zone. 
     
     
         19 . The process as in any of  claims 1 - 18 , wherein the middle distillates in the second ADU fraction comprise
 kerosene that is processed in a kerosene sweetening process to recover a kerosene fuel product, and   a straight run diesel fraction that is the portion of the second ADU fraction that is processed in the distillate hydroprocessing zone.   
     
     
         20 . The process as in  claim 19 , further wherein the middle distillates in the second ADU fraction comprise heavy atmospheric gas oil that is processed in the fluid catalytic cracking zone. 
     
     
         21 . The process as in any of  claims 1 - 20 , wherein non-olefinic C4s recovered from the mixed product stream are recycled to the mixed feed stream cracking zone. 
     
     
         22 . The process as in any of  claims 1 - 19 , wherein non-olefinic C4s recovered from the mixed product stream are recycled to the separate processing zone for production of additional petrochemicals. 
     
     
         23 . The process as  claim 22 , further comprising
 recovering C5s from the hydrotreated pyrolysis gas;   passing the recovered C5s to the separate processing zone for production of additional petrochemicals;   passing a portion of the recovered ethylene to the separate processing zone;   wherein the separate processing zone carries is a metathesis reaction zone which produces petrochemical propylene and a C4/C5 raffinate stream that is recycled to the mixed feed stream cracking zone.   
     
     
         24 . An integrated process for producing petrochemicals and fuel product comprising
 (a) providing
 (a)(1) a mixed feed steam cracking zone receiving a plurality of feeds from multiple sources, and outputting a mixed C1-C4 stream, a py-gas stream and a py-oil stream; 
 (a)(2) a fluid catalytic cracking zone operating under conditions effective for high olefin production, receiving a VGO stream, and outputting a C2− stream, a C3-C4 stream, a FCC naphtha stream, and one or more cycle oil streams; 
 (a)(3) an olefins recovery zone receiving the mixed C1-C4 stream from the mixed feed steam cracking zone, and outputting an ethane stream, a hydrogen gas stream, a fuel gas stream, an ethylene stream, a mixed C3s stream and a mixed C4s stream; and 
 (a)(4) an aromatics extraction zone receiving the py-gas stream, and outputting BTX products and a raffinate stream; 
   (b) charging the plurality of feeds to the mixed feed steam cracking zone, the plurality of feeds including an LPG stream, a straight run naphtha stream, the ethane stream from the olefins recovery zone and the raffinate stream from the aromatics extraction zone;   (c) passing the mixed C1-C4 stream to the olefins recovery zone for separation into at least the ethane stream, the hydrogen gas stream, the fuel gas stream, the ethylene stream, the mixed C3s stream and the mixed C4s stream, and recycling the ethane stream to the mixed feed steam cracking zone;   (d) hydrotreating all or a portion of the py-gas stream, and passing the hydrotreated py-gas stream to the aromatics extraction zone for separation into BTX and the raffinate stream, and routing the raffinate stream to the mixed feed steam cracking zone;   (e) charging the VGO stream to the fluid catalytic cracking zone for production of and separation into the C2− stream, the C3-C4 stream, the FCC naphtha stream, and the one or more cycle oil streams.   
     
     
         25 . The integrated process as in  claim 24 , further comprising routing hydrotreated naphtha, derived from hydrotreating a straight run diesel stream, to the mixed feed steam cracking zone as an additional one of the plurality of feeds, and further comprising recovering a diesel fuel stream. 
     
     
         26 . The integrated process as in  claim 25 , wherein a source of hydrogen for the step of hydrotreating all or a portion of the straight run diesel stream is from the olefins recovery zone. 
     
     
         27 . The integrated process as in  claim 24 , further comprising routing hydrotreated naphtha, derived from hydrotreating a portion of a kerosene stream, to the mixed feed steam cracking zone as an additional one of the plurality of feeds, and further comprising recovering a diesel fuel stream. 
     
     
         28 . The integrated process as in  claim 27 , wherein the portion of the kerosene stream that is hydrotreated is a heavy kerosene stream. 
     
     
         29 . The integrated process as in  claim 27 , further comprising hydrotreating a medium AGO stream with the heavy kerosene stream. 
     
     
         30 . The integrated process as in  claim 27 , wherein a source of hydrogen for the step of hydrotreating the portion of a kerosene stream is from the olefins recovery zone. 
     
     
         31 . The integrated process as in  claim 24 , wherein the LPG stream, the straight run naphtha stream, the AGO stream and the VGO stream are derived from a common crude oil feed. 
     
     
         32 . The integrated process as in  claim 25 , wherein the LPG stream, the straight run naphtha stream, the straight run diesel stream and the VGO stream are derived from a common crude oil feed. 
     
     
         33 . The integrated process as in  claim 31  or  31 , wherein the common crude oil feed is Arab Extra Light crude oil. 
     
     
         34 . The integrated process as in  claim 31  or  31 , wherein the common crude oil feed is Arab Light crude oil. 
     
     
         35 . The integrated process as in  claim 31  or  31 , further comprising subjecting a kerosene fraction from the common crude oil feed to a kerosene sweetening process to recover a jet fuel product. 
     
     
         36 . The integrated process as in  claim 24 , further comprising hydrotreating all or a portion of the FCC naphtha stream to produce a hydrotreated FCC naphtha stream, and routing all or a portion of the hydrotreated FCC naphtha stream to the aromatics extraction zone. 
     
     
         37 . The integrated process as in  claim 36 , wherein a source of hydrogen for hydrotreating all or a portion of the FCC naphtha stream is from the olefins recovery zone. 
     
     
         38 . The integrated process as in  claim 36 , wherein hydrotreating of all or a portion of the py-gas stream occurs in a different reactor than hydrotreating of all or a portion of the FCC naphtha stream. 
     
     
         39 . The integrated process as in  claim 38 , wherein
 a source of hydrogen for hydrotreating all or a portion of the py-gas stream is from the olefins recovery zone, and   a source of hydrogen for hydrotreating all or a portion of the FCC naphtha stream is from the olefins recovery zone.   
     
     
         40 . The integrated process as in  claim 36 , wherein hydrotreating of all or a portion of the py-gas stream occurs in the same reactor as the hydrotreating of all or a portion of the FCC naphtha stream. 
     
     
         41 . The integrated process as in  claim 40 , wherein a source of hydrogen for hydrotreating all or a portion of the py-gas stream and all or a portion of the FCC naphtha stream is from the olefins recovery zone. 
     
     
         42 . The integrated process as in  claim 24 , wherein a source of hydrogen for hydrotreating all or a portion of the py-gas stream is from the olefins recovery zone. 
     
     
         43 . The integrated process as in  claim 24 , further comprising hydrotreating all or a portion of an AGO stream, all or a portion of the VGO stream, or a combination of all or a portion of the AGO stream and all or a portion of the VGO stream, to produce a hydrotreated naphtha stream, a diesel fuel stream and hydrotreated gas oil stream, wherein the hydrotreated gas oil stream is the feed to the fluid catalytic cracking zone. 
     
     
         44 . The integrated process as in  claim 43 , wherein a source of hydrogen for hydrotreating is from the olefins recovery zone. 
     
     
         45 . The integrated process as in  claim 43 , wherein the hydrotreated naphtha stream is routed to the mixed feed steam cracking zone as an additional one of the plurality of feeds. 
     
     
         46 . The integrated process as in  claim 43 , comprising hydrotreating a feed comprising heavy AGO from the AGO stream and the VGO stream. 
     
     
         47 . The integrated process as in  claim 24 , further comprising
 hydrotreating all or a portion of an AGO stream, all or a portion of the VGO stream, or a combination of all or a portion of the AGO stream and all or a portion of the VGO stream, to produce a distillates stream, a diesel fuel stream and a hydrotreated gas oil stream, wherein the hydrotreated gas oil stream is the feed to the fluid catalytic cracking zone; and   routing hydrotreated naphtha, derived from hydrotreating a straight run diesel stream, to the mixed feed steam cracking zone as an additional one of the plurality of feeds, and further comprising recovering a diesel fuel stream from the straight run diesel stream and the distillates stream.   
     
     
         48 . The integrated process as in  claim 47 , wherein a source of hydrogen for hydrotreating all or a portion of the straight run diesel stream is from the olefins recovery zone. 
     
     
         49 . The integrated process as in  claim 47  or  48 , wherein a source of hydrogen for hydrotreating all or a portion of the AGO stream and/or all or a portion of the VGO stream is from the olefins recovery zone. 
     
     
         50 . The integrated process as in  claim 47 , wherein the distillates stream from the hydrotreating zone (GOHT) is hydrotreated with the straight run diesel stream. 
     
     
         51 . The integrated process as in  claim 47 , comprising hydrotreating a feed comprising heavy AGO from the AGO stream and the VGO stream. 
     
     
         52 . The process as in  claim 24 , wherein the olefins recovery zone includes cooling, compression, caustic washing, and one or more distillation steps for separation into hydrogen, fuel gas, ethane that is recycled to the mixed feed steam cracking zone, ethylene, mixed C3s and mixed C4s. 
     
     
         53 . The process as in  claim 24 , further comprising passing light olefin intermediate product from the fluid catalytic cracking zone subjected to an unsaturated gas reaction zone to the olefins recovery zone. 
     
     
         54 . The process as in  claim 53 , further comprising subjected the mixed C3s from the olefins recovery zone to methyl acetylene/propadiene (MAPD) saturation by reaction with hydrogen to produce a saturated mixed C3 intermediate, wherein the saturated mixed C3 intermediate contains a reduced proportion of methyl acetylene/propadiene compared to the mixed C3s from the olefins recovery zone and an increased proportion of propylene. 
     
     
         55 . The process as in  claim 54 , further comprising separating propylene from other mixed C3 compounds in the saturated mixed C3 intermediate. 
     
     
         56 . The process as in  claim 55 , further comprising recycling the other mixed C3 compounds to the mixed feed steam cracking zone.