Production of btx aromatics and light gas olefins from crude oil and plastic pyrolysis oil

Abstract

A process for producing C 6 to C 8 aromatics and optionally light gas olefins from crude oil and/or pyrolysis oil is disclosed. The process can include hydroprocessing a first stream containing hydrocarbons from the crude oil and/or pyrolysis oil to obtain a second stream containing saturated hydrocarbons having boiling point less than 350° C., separating the second stream to obtain a third stream containing hydrocarbons having boiling point less than 70° C., a fourth stream containing hydrocarbons having boiling point 70° C. to 140° C., and a fifth stream containing hydrocarbons having boiling point greater than 140° C., recycling at least a portion of the fifth stream to the hydroprocessing step, reforming the fourth stream to obtain a sixth stream containing C 6 to C 8 aromatics, and optionally cracking the third stream to obtain light gas olefins.

1 . A process for selectively producing C 6  to C 8  aromatics and optionally light gas olefins, the process comprising:
 a) hydroprocessing a first stream comprising hydrocarbons from crude oil and/or pyrolysis oil to obtain a second stream comprising saturated hydrocarbons having boiling point less than 350° C.;   b) separating the second stream to obtain a third stream comprising hydrocarbons having boiling point less than 70° C., a fourth stream comprising hydrocarbons having boiling point 70° C. to 140° C., and a fifth stream comprising hydrocarbons having boiling point greater than 140° C.;   c) recycling at least a portion of the fifth stream to the hydroprocessing step (a);   d) reforming the fourth stream to obtain a sixth stream comprising C 6  to C 8  aromatics; and   e) optionally cracking the third stream and/or a portion of the fifth stream to obtain light gas olefins.   
     
     
         2 . The process of  claim 1 , wherein at least 70 wt. % of the second stream is comprised of the saturated hydrocarbons having boiling point less than 350° C. 
     
     
         3 . The process of  claim 1 , wherein reforming step d) further comprises obtaining a seventh stream comprising non-aromatics and non C 6  to C 8  aromatics and optionally recycling at least a portion of the seventh stream to the hydroprocessing step (a). 
     
     
         4 . The process of  claim 1 , wherein the hydroprocessing conditions in step (a) comprise a pressure lower than 100 barg, preferably 30 barg to 100 barg, a temperature 300° C. to 600° C., weight hourly space velocity 0.5 to 2 hr −1 , or H 2 :hydrocarbon volume ratio of 200 Nm 3 :1 m 3  to 2000 Nm 3 :1 m 3  of liquid feed, or any combinations or all thereof. 
     
     
         5 . The process of  claim 4 , wherein the hydroprocessing in step (a) is performed using a dissolved catalyst comprising Ni and/or Mo, and a fixed bed catalyst comprising Co, Mo, Ni, W, or any combinations thereof on a support. 
     
     
         6 . The process of  claim 1 , wherein the reforming conditions in step (b) comprise a temperature of 450° C. to 550° C., a pressure of 2 barg to 30 barg, or H 2 :hydrocarbon mole ratio of 2:1 to 9:1, or any combinations or all thereof. 
     
     
         7 . The process of  claim 1 , wherein the reforming in step (d) is performed using a reforming catalyst comprising Pt—Re on alumina, Pt on alumina, metal loaded zeolite, or a combinations thereof. 
     
     
         8 . The process of  claim 1 , wherein the pyrolysis oil is obtained from plastic. 
     
     
         9 . The process of  claim 8 , wherein the pyrolysis oil is obtained from the plastic by depolymerizing the plastic at a depolymerization temperature sufficient to produce a hydrocarbonaceous wax stream; and cracking the hydrocarbonaceous wax stream in the presence of a cracking catalyst under cracking conditions sufficient to produce the pyrolysis oil, wherein the cracking conditions include a cracking temperature that is higher than, or equal to, or lower than the depolymerization temperature. 
     
     
         10 . The process of  claim 1 , wherein the first stream comprises hydrocarbons having boiling point above 140° C. separated from the crude oil and/or the pyrolysis oil by atmospheric distillation. 
     
     
         11 . The process of  claim 10 , wherein the atmospheric distillation further produces a eighth stream comprising hydrocarbons having boiling points of 70° C. to 140° C., and the process further comprises reforming the eighth stream. 
     
     
         12 . The process of  claim 10 , wherein eight stream is reformed with the fourth stream to form the sixth stream and the seventh stream. 
     
     
         13 . The process of  claim 10 , wherein the atmospheric distillation further produces a ninth stream comprising hydrocarbons having boiling point below 70° C. 
     
     
         14 . The process of  claim 13 , wherein the ninth stream is cracked with the third stream to produce the light gas olefins or is sent to the hydroprocessing step. 
     
     
         15 . The process of  claim 1 , wherein the first stream comprises pyrolysis oil. 
     
     
         16 . The process of  claim 1 , wherein the first stream comprises condensate, naphtha, light crude oil, or a crude oil hydrocarbon fraction having an upper boiling point cut of 350° C. or whole crude oil, or any combinations or all thereof. 
     
     
         17 . A process for selectively producing C 6  to C 8  aromatics and optionally light gas olefins from plastics, the process comprising:
 a) performing reactive extrusion or melt cracking of plastics to form pyrolysis oil;   b) separating the pyrolysis oil to obtain a stream A comprising hydrocarbons having boiling point less than 70° C., a stream B comprising hydrocarbons having boiling point 70° C. to 140° C., and a stream C comprising hydrocarbons having boiling point greater than 140° C.;   c) reforming the stream B to obtain a stream D comprising C 6  to C 8  aromatics; and   d) optionally mixing the stream A to a gasoline pool of a refinery.   
     
     
         18 . The process of  claim 17 , wherein the reactive extrusion or melt cracking of plastics comprises, depolymerizing of the plastic at a depolymerization temperature sufficient to produce a hydrocarbonaceous wax stream; and catalytic cracking the hydrocarbonaceous wax stream in presence of a cracking catalyst under cracking conditions sufficient to produce the pyrolysis oil, wherein the cracking conditions include a cracking temperature that is higher than, or equal to, or lower than the depolymerization temperature. 
     
     
         19 . The process of  claim 18 , further comprising recycling the stream C to the catalytic cracking step. 
     
     
         20 . The process of  claim 18 , wherein at least a portion of hydrogen containing gases, non-aromatics, and non C 6  to C 8  aromatics obtained from reforming in step (c) is recycled to the catalytic cracking step.