Direct Catalytic Cracking of Crude Oil Using Temperature Gradient Process

Abstract

A direct catalytic cracking system for converting undistilled and unfractionated hydrocarbon material into hydrocarbon products comprising light olefins and C6-8 aromatics. The direct catalytic cracking system includes a moving catalyst bed reactor having one or more catalytic reaction zones and configured to be able to adjust its internal temperature. The direct catalytic cracking system also includes a catalyst regeneration system. A method of converting undistilled and unfractionated hydrocarbon material to hydrocarbon products utilizing the direct catalytic cracking system. The method includes the step of introducing a moving bed reactor feed comprising steam and undistilled and unfractionated hydrocarbon material. The method further comprises the steps of introducing a direct cracking catalyst into a catalytic reaction zone of a moving catalyst bed reactor, operating the direct catalytic cracking system to convert hydrocarbon material to product hydrocarbons in the presence of the direct cracking catalyst, and extracting from The moving catalyst bed reactor discharges product hydrocarbons.

Description

technical field [0001] The field of the invention relates to methods and systems for converting undistilled and unfractionated hydrocarbon material into product hydrocarbons. More specifically, the field of the invention relates to systems and methods for converting hydrocarbon material, particularly undistilled and unfractionated crude oil, into hydrocarbon products comprising a mixture of light olefins and C6-8 aromatics . Background technique [0002] With the growing global awareness related to our use of non-renewable resources (including crude oil, gas condensate and natural gas) as the basis for making transportation fuels, the long-term upward trend in the use of gasoline and diesel fuel may finally stabilize, even in the next decades to come, even taking into account the increase in global population. However, the overall demand for petrochemical products or chemicals partially derived from hydrocarbon materials will continue to rise. Human society and its contin...

AI Technical Summary

Problems solved by technology

There are two main challenging issues for the cracking of hydrocarbon feeds in the full boiling point range, which prevent the application of these two processes: due to the formation of coke and poisons from heavy metals and Catalyst contamination, leading to rapid catalyst deactivation, making it difficult to use catalyst-based systems

The wide temperature range over which "crackable" crude oil groups crack leads to problems with process control and long-term system integrity (i.e., temperature / time based stress failure) for purely thermal processes

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