Process for producing olefins and aromatics through hydro pyrolysis and coke management

Abstract

Systems and processes for producing olefins and aromatics. A process can include contacting a first hydrocarbon feed with a catalyst and a hydrogen source under conditions sufficient to produce a used catalyst and an intermediate stream containing olefins and aromatics, and contacting the used catalyst with the intermediate stream and a coke precursor feed to produce a spent coked catalyst and a products stream comprising additional olefins and aromatics.

What is claimed is: 
     
         1 . A hydropyrolysis process to produce higher yields of olefins and aromatics, the process comprising:
 (a) contacting a first hydrocarbon feed stream comprising a first hydrocarbon with a cracking catalyst and a hydrogen source under conditions sufficient to produce a used catalyst and an intermediate stream comprising olefins and aromatics; and   (b) contacting the used catalyst and the intermediate stream with a coke precursor stream to produce a spent coked catalyst and a products stream comprising additional olefins and aromatics.   
     
     
         2 . The hydropyrolysis process of  claim 1 , wherein a catalyst to feed (C/F) ratio in step (a) is greater than the C/F ratio in step (b). 
     
     
         3 . The hydropyrolysis process of  claim 1 , wherein the wt. % of coke in the used catalyst is lower than the wt. % of coke in the spent coked catalyst. 
     
     
         4 . The hydropyrolysis process of  claim 1 , wherein the process further comprises regenerating the spent coked catalyst. 
     
     
         5 . The hydropyrolysis process of  claim 4 , wherein the regenerated catalyst is recycled to step (a). 
     
     
         6 . The hydropyrolysis process of  claim 1 , wherein the hydrogen source is hydrogen (H 2 ) gas, methane, ethane, ethylene, propane, propylene, butanes, butenes or any combinations thereof. 
     
     
         7 . The hydropyrolysis process of  claim 1 , wherein the contacting condition in step (a) comprises a temperature of 500° C. to 750° C. 
     
     
         8 . The hydropyrolysis process of  claim 1 , wherein the contacting condition in step (a) comprises a temperature of 700° C. to 850° C. 
     
     
         9 . The hydropyrolysis process of  claim 1 , wherein the first hydrocarbon feed stream comprises naphtha, condensates, gas oils, C 3  and C 4  saturated gas, cracked naphtha stream, recycled crackable hydrocarbon stream comprising C 3  and C 4  saturated gas or any combinations thereof. 
     
     
         10 . The hydropyrolysis process of  claim 1 , wherein the coke precursor stream comprises cycle oils, coker streams, crude oil, slurry oil, carbon black oil, cracked distillates, cracked oils, vacuum residue or any combination thereof. 
     
     
         11 . The hydropyrolysis process of  claim 1 , further comprising providing a second hydrocarbon feed stream comprising a second hydrocarbon to step (a), and the intermediate stream is produced by contacting the catalyst with the first hydrocarbon feed stream and the second hydrocarbon feed stream, wherein the average molecular weight of the second hydrocarbon feed stream is higher than the average molecular weight of the first hydrocarbon feed stream. 
     
     
         12 . The hydropyrolysis process of  claim 11 , wherein the second hydrocarbon feed stream comprises crude oil, atmospheric residue, vacuum gas oils, unconverted oil from hydrocrackers, hydrowax, polyolefin oligomers, plastics or polymers dissolved or slurried in solvents, plastics, partially depolymerized plastics, plastic pyrolysis oil, hydrogenated plastic pyrolysis oil, recycled naphtha and gas oil streams, naphtha, gas oils, vacuum gas oil and unconverted oil products from hydrocracking of plastics or any combinations thereof. 
     
     
         13 . The hydropyrolysis process of  claim 11 , wherein the second hydrocarbon feed stream is contacted with the catalyst downstream to contacting the catalyst with the first hydrocarbon feed stream. 
     
     
         14 . The hydropyrolysis process of  claim 11 , further comprising providing a third hydrocarbon feed stream comprising a third hydrocarbon to step (a), and the intermediate stream is produced by contacting the catalyst with the first hydrocarbon feed stream, the second hydrocarbon feed stream and the third hydrocarbon feed stream wherein the average molecular weight of the third hydrocarbon stream is higher than the average molecular weight of the second hydrocarbons stream. 
     
     
         15 . The hydropyrolysis process of  claim 14 , wherein the third hydrocarbon feed stream comprises crude oil, atmospheric residue, vacuum gas oils, unconverted oil from hydrocrackers, hydrowax, polyolefin oligomers, polymers dissolved or slurried in solvents, plastics, partially depolymerized plastics, plastic pyrolysis oil, hydrogenated plastic pyrolysis oil, heavy recycled crackable hydrocarbon stream, gas oils, vacuum gas oil and unconverted oil products from hydrocracking of plastics or any combinations thereof. 
     
     
         16 . The hydropyrolysis process of  claim 14 , wherein the third hydrocarbon feed stream is contacted with the catalyst downstream to contacting the catalyst with the second hydrocarbon feed stream. 
     
     
         17 . The hydropyrolysis process of  claim 1 , wherein the step (a) and (b) is performed in a reactor and average hydrocarbon residence time in the reactor is 100 ms to 2 sec, preferably 100 ms to 1 sec. 
     
     
         18 . The hydropyrolysis process of  claim 17 , wherein the hydrogen source is provided to step (a) comprised in a lift stream and the lift stream can further comprise steam. 
     
     
         19 . The hydropyrolysis process of  claim 17 , further comprising feeding an oxygenate at one or more positions of the reactor. 
     
     
         20 . The hydropyrolysis process of  claim 19 , wherein the process further comprises controlling local temperature of the reactor at the one or more positions where the oxygenate is fed:
 measuring the local temperature at the one or more positions where the oxygenate is fed; and   increasing the oxygenate flow rate to the reactor if the local temperature at the one or more positions is lower than a desired temperature at the one or more positions or decreasing the oxygenate flow rate to the reactor if the local temperature at the one or more positions is higher than a desired temperature at the one or more positions.