Naphtha splitter integration with hncc technology

Abstract

Systems and methods for processing full range naphtha and producing light olefins and BTX are disclosed. Full range naphtha is separated in naphtha splitter to produce a light naphtha stream and a heavy naphtha stream. The heavy naphtha stream is then fed to a heavy naphtha catalytic cracker to produce a cracked stream. The effluent from the steam cracking unit and the effluent from the catalytic cracking unit may be flowed into an oil quench tower and are further separated in a separation unit to produce purified ethylene, propylene, butadiene, 1-butene, and BTX. The cracked stream maybe further processed. The light naphtha stream or both the lights stream combined with the light naphtha stream is fed to a steam cracker to produce an effluent stream comprising olefins. Effluent of the steam cracker is fed to the processing unit to separate light olefins. The C 6 + hydrocarbons from the processes may be recycled.

1 . A method of processing full range naphtha, the method comprising: feeding the full range naphtha to a naphtha splitter, the full range naphtha having an initial boiling point (IBP) of 30 to 50° C. and a final boiling point of 210 to 220° C.; separating the full range naphtha by the naphtha splitter, to produce a heavy naphtha stream having an IBP of 60 to 65° C. and a FBP of 210 to 220° C. and a light naphtha stream having an IBP of 30 to 35° C. and a FBP of 40 to 60° C.; catalytically cracking the heavy naphtha stream to produce a cracked stream; and processing the cracked stream in a processing unit to produce C 2  to C 4  olefins, benzene, toluene, and xylene. 
     
     
         2 . A method of producing olefins and/or BTX, the method comprising: splitting a feed stream comprising naphtha that has an initial boiling point in a range of 30 to 50° C. and a FBP in a range of 210 to 220° C. to form a first stream comprising heavy naphtha that has an initial boiling point in a range of 60 to 65° C. and a final boiling point in a range of 210 to 220° C. and a second stream comprising light naphtha that has an initial boiling point in a range of 30 to 35° C. and a final boiling point in a range of 40 to 60° C.; contacting the first stream with a catalyst under catalytic cracking conditions sufficient to cause cracking of hydrocarbons in the first stream to form a first intermediate product stream comprising one or more of: ethylene, propylene, butene, benzene, toluene, and xylene; and subjecting the second stream to steam cracking conditions that comprises a temperature above 800° C. to convert hydrocarbons in the second stream and thereby form a second intermediate product stream comprising one or more of: ethylene, propylene, butene, benzene, toluene, and xylene. 
     
     
         3 . A method of processing full range naphtha, the method comprising: feeding the full range naphtha to a naphtha splitter, the full range naphtha having an initial boiling point (IBP) of 30 to 50° C. and a final boiling point of 210 to 220° C.; separating the full range naphtha by the naphtha splitter, to produce a heavy naphtha stream having an IBP of 60 to 65° C. and a FBP of 210 to 220° C. and a light naphtha stream having an IBP of 30 to 35° C. and a FBP of 40 to 60° C.; catalytically cracking the heavy naphtha stream to produce a cracked stream; processing the cracked stream to produce a stream comprising primarily C 2  to C 4  olefins, benzene, toluene, xylene, collectively, a lights stream comprising primarily C 2  to C 4  hydrocarbons, and a heavies stream comprising primarily C 5  to C 12  hydrocarbons; combining the light naphtha stream with the lights stream to form a combined lights stream; and steam cracking the combined lights stream to produce olefins. 
     
     
         4 . The method of  claim 1 , further comprising steam cracking the light naphtha stream to produce olefins. 
     
     
         5 . The method of  claim 1 , wherein the processing further produces a lights stream comprising primarily C 2  to C 4  hydrocarbons, and a heavies stream comprising primarily C 5  to C 12  hydrocarbons. 
     
     
         6 . The method of  claim 5 , further comprising: combining the light naphtha stream with the lights stream to form a combined lights stream; and steam cracking the combined lights stream to produce a cracked lights stream comprising olefins. 
     
     
         7 . The method of  claim 6 , further comprising processing the cracked lights stream in the processing unit to produce additional C 2  to C 4  olefins. 
     
     
         8 . The method of  claim 6 , wherein the steam cracking is performed under process conditions including a cracking temperature of 800 to 950° C. and a residence time of 5 to 10000 ms. 
     
     
         9 . The method of  claim 6 , further comprising: combining the heavies stream and the heavy naphtha stream to form a combined heavies stream; and catalytically cracking the combined heavies stream. 
     
     
         10 . The method of  claim 1 , wherein the naphtha splitter comprises heat exchangers, distillation columns, separators, pumps, absorbers, adsorbers, or combinations thereof. 
     
     
         11 . The method of  claim 1 , wherein the naphtha splitter is operated under process conditions including an operating temperature of 30 to 50° C. 
     
     
         12 . The method of  claim 1 , wherein the naphtha splitter is operated under process conditions including an operating pressure of 1 to 5 bar. 
     
     
         13 . The method of  claim 1 , wherein the catalytically cracking is performed under process conditions including an operating temperature of 600 to 750° C. 
     
     
         14 . The method of  claim 1 , wherein the catalytically cracking is performed under process conditions including an operating pressure of 1 to 4 bar. 
     
     
         15 . The method of  claim 1 , wherein the catalytically cracking is performed in the presence of a molecular sieve based catalyst. 
     
     
         16 . The method of  claim 1 , wherein the processing of the cracked stream comprises compressors, separators, heat exchangers, pumps, dryers, coolers, reactors, distillation columns, extraction columns, or combinations thereof. 
     
     
         17 . The method of  claim 1 , wherein the full range naphtha is obtained from distilling crude oil. 
     
     
         18 . The method of  claim 1 , wherein the processing of the cracked stream comprises compressors. 
     
     
         19 . The method of  claim 1 , wherein the processing of the cracked stream comprises separators. 
     
     
         20 . The method of  claim 1 , wherein the processing of the cracked stream comprises distillation columns.