System and method for producing olefins and / or aromatics by water treatment and steam cracking

Abstract

Systems and methods for producing olefins and / or aromatics are disclosed. These processes include high strength water treatment of crude oil and / or heavy oil prior to steam cracking unit processing to produce ethylene and propylene with a propylene to ethylene mass ratio (P / E) of 0.6 or greater. The system comprises a water treatment device capable of operating at high intensity and a steam cracking device capable of producing ethylene and propylene at a propylene to ethylene mass ratio (P / E) of 0.6 or higher.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] none. A. Technical field

[0002] The present invention generally relates to the production of olefins and / or aromatic compounds. More specifically, the present invention relates to the production of olefins and / or aromatics from crude oil and / or heavy oil by water treatment followed by steam cracking. B. Background Technology

[0003] In the process of processing crude oil to produce olefins and / or aromatics, multiple hydrocracking units are used to upgrade the heavy ends of the crude oil; steam cracking units are used to maximize ethylene production. The economics of this processing method are negatively affected by high capital expenditures, low ethylene to propylene ratios (E / P ratios), and methane losses. The investment in crude oil chemical plants is very high; this is at least partially caused by the high cost of steam crackers and hydrocrackers. High conversion of the crude oil stream in the hydrocracker and subsequent maximization of the E / P ratio in the steam cracker result in reduced carbon efficiency because more methane is produced. For crude oil chemical processing plants to be viable, the economics and chemical output of these plants must be improved. Summary of the invention

[0004] The inventors have found a method to solve one or more of the above problems. According to an embodiment of the present invention, the solution includes producing olefins and / or aromatics by high-intensity water treatment of crude oil and / or heavy ends, followed by low-intensity cracking. As a supplement or replacement for conventional crude oil feeds, plastics, plastic pyrolysis oligomers, synthetic crude oil or hydrocarbon streams produced by plastic pyrolysis can also be co-processed. In addition, in embodiments of the present invention, bio-oil can be co-processed with crude oil, or as a substitute for crude oil.

[0005] Embodiments of the present invention include a method for producing olefins and / or aromatics. The method includes flowing a hydrocarbon feed and hydrogen into a water treatment unit in which a catalyst is disposed, and water treating the hydrocarbon feed in the water treatment unit to produce a first stream comprising a gas having a boiling point below 200°C, producing a second stream having a boiling point of 200°C to 350°C, and a third stream comprising one or more of asphalt, coke or fuel oil and having a boiling point of 350°C to 650°C. The water treatment of the hydrocarbon feed includes contacting the hydrocarbon feed and hydrogen with a catalyst in a temperature range of 400 to 500°C. The method also includes flowing the first stream and the second stream to a steam cracking unit; and treating the first stream and the second stream in the steam cracking unit to produce olefins and / or aromatics. The olefins include ethylene and propylene, and the mass ratio of propylene to ethylene (P / E) when the steam cracking unit is operated is 0.6 to 0.68. The water treatment is to hydrocracking hydrocarbons in the presence of (a) one or more catalysts and (b) a solvent that keeps asphaltenes dissolved at a temperature ranging from 280 to 550°C and a pressure ranging from 40 to 200 barg. In an embodiment of the present invention, the water treatment conditions may include a liquid feed with a hydrogen-to-hydrocarbon ratio of 200 to 2000 NL / L, and the water treatment may be performed with or without the addition of steam.

[0006] Embodiments of the present invention include a system for producing olefins and / or aromatics. The system for producing olefins and / or aromatics includes a water treatment unit, in which a catalyst is disposed, and is suitable for contacting a hydrocarbon feed and hydrogen with the catalyst in a temperature range of 400 to 500°C to produce a first stream, the first stream comprising a gas having a boiling point below 200°C, a second stream having a boiling point in the range of 200 to 350°C, and a third stream comprising one or more of asphalt, coke or fuel oil and having a boiling point in the range of 350 to 650°C. The system further includes a steam cracking unit in fluid communication with the water treatment unit, wherein the steam cracking unit is suitable for producing olefins and / or aromatics from the first stream and the second stream.

[0007] Included below are definitions of various terms and phrases used throughout this specification.

[0008] The term "about" or "approximately" is defined as close to the degree understood by those of ordinary skill in the art. In a non-limiting embodiment, these terms are defined as within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

[0009] For the purposes of this disclosure, “X, Y, and / or Z” may be understood as only X, only Y, only Z, or any combination of two or more items X, Y, and Z (e.g., XYZ, XY, XZ, YZ).

[0010] The terms "wt. %, "vol. %" or "mol. %" refer to the weight, volume or mole percentage based on the total weight, total volume or total moles of the material containing the component, respectively. In a non-limiting example, 100 moles of a material containing 10 moles of a component is 10 mol. % of the component.

[0011] The term "substantially" and variations thereof are defined to include ranges within 10%, within 5%, within 1%, or within 0.5%.

[0012] The terms "inhibit" or "reduce" or "prevent" or "avoid" or any variation of these terms as used in the claims and / or description include any measurable reduction or complete inhibition to achieve the desired effect.

[0013] The term "effective" as used in the specification and / or claims means sufficient to achieve an intended, desired, or purposeful result.

[0014] The terms "a" or "an" used in conjunction with the terms "comprising," "including," "containing," or "having" in the claims or description may mean "one," but are also consistent with the meaning of "one or more," "at least one," and "one or more."

[0015] The words "comprise" (and any form of inclusion, such as "include" and "contain"), "have" (and any form of having, such as "have" and "contain"), "include" (and any form of inclusion, such as "includes" and "contain"), or "contains" (and any form of containing, such as "including" and "having") are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0016] The processes of the present invention may "comprise," "consist essentially of," or "consist of" the particular ingredients, compositions, compositions, etc. disclosed throughout the specification.

[0017] The term "mainly" used in the specification and / or claims refers to any one of greater than 50 wt.%, 50 mol.%, and 50 vol.%. For example, "mainly" may include 50.1 wt.% to 100 wt.% and all values ​​and ranges therebetween, 50.1 mol.% to 100 mol.% and all values ​​and ranges therebetween, or 50.1 vol.% to 100 vol.% and all values ​​and ranges therebetween.

[0018] Other objects, features and advantages of the present invention will be apparent from the following figures, detailed descriptions and examples. However, it should be understood that these figures, detailed descriptions and examples, although indicating specific embodiments of the present invention, are for illustrative purposes only and are not intended to be limiting. In addition, changes and modifications within the spirit and scope of the present invention will also be apparent to those skilled in the art. In more embodiments, the features of a particular embodiment may be combined with the features of other embodiments. For example, the features of one embodiment may be combined with the features of any other embodiment. In more embodiments, other features may also be added to the specific embodiments described herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] For a more complete understanding, reference is now made to the following description taken in conjunction with the accompanying drawings, in which:

[0020] Figure 1 A system for producing olefins and / or aromatics according to an embodiment of the present invention is shown; and

[0021] Figure 2 A method for producing olefins and / or aromatics according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0022] The present invention relates to an enhanced upgrading process for heavy tail of crude oil - water treatment. Such water treatment can replace multiple conventional hydrocracking units in a crude oil chemical plant. According to an embodiment of the present invention, the water treatment unit is operated at a high load to maximize the conversion into low boiler steam cracking feedstock, and then the steam cracking unit is operated at a low load to increase the chemical production. According to an embodiment of the present invention, products from high load water treatment and low concentration steam cracking can produce high value chemicals such as olefins and / or aromatics.

[0023] Figure 1 A system 10 for producing olefins and / or aromatics according to an embodiment of the present invention is shown. Figure 2 A method 20 for producing olefins and / or aromatics according to an embodiment of the present invention is shown. In an embodiment of the present invention, the method 20 is implemented by the system 10. Systems for producing olefins and / or aromatics

[0024] Figure 1A system 10 is shown that includes a separation device 103 (e.g., a flash vessel, a distillation column, and / or a stripping device), which in an embodiment of the present invention is suitable for separating (a) crude oil 100 and / or (b) a first heavy oil stream 101, the device including a flash vessel, a distillation column, and / or a stripping unit (where (a) and (b) form a combined stream 102) to produce (1) a top crude oil cut stream 104 having a boiling point range below 200°C and (2) a bottom crude oil cut stream 105 having a boiling point above 200°C. According to an embodiment of the present invention, the system 10 includes a water treatment unit 109, which includes a reactor unit 110 and a separation unit 112. In an embodiment of the present invention, the water treatment unit 109 is adapted to receive a hydrogen gas stream 107 and a hydrocarbon feed 108 containing or not containing water, in an embodiment of the present invention, the hydrocarbon feed 108 includes the bottom crude oil cut stream 105 and the second heavy oil stream 106. According to an embodiment of the present invention, the reactor device 110 is used to receive the hydrocarbon feed 108 and the hydrogen gas stream 107. In an embodiment of the present invention, the reactor unit 110 comprises a fixed bed reactor in which a catalyst is placed and is adapted to contact the hydrogen gas stream 107 and the hydrocarbon feed 108 with the catalyst at a temperature in the range of 400 to 500° C. to produce a first reactor unit effluent 111. In an embodiment of the present invention, the separation unit 112 comprises one or more distillation columns for receiving and separating the reactor unit effluent 111 to produce a first stream 113, a second stream 114 and a third stream 115. According to an embodiment of the present invention, the boiling point range of the first stream 113 is up to 200° C., the boiling point range of the second stream 114 is 200 to 350° C., and the third stream 115 comprises asphalt / coke / fuel oil with a boiling point range of 350 to 650° C.

[0025] In an embodiment of the present invention, the system 10 includes a steam cracking unit 116 in fluid communication with the separation unit 103 and the water treatment unit 109, so that the top crude oil cut stream 104, the first stream 113 and / or the second stream 114 can flow to the steam cracking unit 116 for processing to produce a high-value chemical liquid stream 117, including olefins and / or aromatics. Process for producing olefins and / or aromatics

[0026] Figure 2A method 20 is shown, which in an embodiment of the present invention includes block 200, which involves flowing (a) crude oil 100 and / or (b) a first heavy oil stream 101 (including any combination of crude oil, plastic, hydrocarbons produced by pyrolysis of plastic, bio-oil, hydrogenated bio-oil, oligomers produced by plastic, pyrolysis oil produced by synthetic crude oil and plastic, bottom cuts of crude oil cuts, pyrolysis oils, and heavy residues produced by steam cracking furnaces) to a separation unit 103. At block 201, according to an embodiment of the present invention, the separation unit 103 separates (a) crude oil 100 and / or (b) the first heavy oil stream 101 (wherein (a) and (b) form a combined stream 102) to produce (1) a top crude oil cut stream 104 having a boiling point in the range below 200°C and (2) a bottom crude oil cut stream 105 having a boiling point above 200°C. At block 202, in an embodiment of the present invention, the method 20 includes flowing the bottom crude oil cut stream 105 and / or the second heavy oil stream 106 to a water treatment unit 109. In an embodiment of the present invention, the bottom crude oil cutting stream 105 and / or the second heavy oil stream 106 are mixed with water or not to form a hydrocarbon feed 108. At block 203, according to an embodiment of the present invention, the hydrogen stream 107 and the hydrocarbon feed 108 flow to the reactor unit 110. At block 204, according to an embodiment of the present invention, the reactor unit 110 includes one or more of a fixed bed reactor, a boiling reactor and a slurry reactor, and a catalyst (e.g., a catalyst composed of one or more of the following: an organic metal compound having one or more of Ni, Mo, Co, W, Zr; NiMo; NiCoMo; NiMoW; alumina; and / or zeolite) is arranged therein for contacting the hydrocarbon feed 108 and the hydrogen stream 107 with the catalyst at a temperature range of 400 to 500° C. to produce a reactor unit effluent 111. In an embodiment of the present invention, at block 205, the reactor unit effluent 111 flows to a separation unit 112. At block 206, in an embodiment of the present invention, a separation unit 112 (which may include one or more distillation columns) receives and separates the reactor unit effluent 111 to produce a first stream 113, a second stream 114, and a third stream 115. According to an embodiment of the present invention, the first stream 113 is a gas with a boiling point range of up to 200°C, the second stream 114 has a boiling point range of 200 to 350°C, and the third stream 115 includes asphalt coke and / or fuel oil with a boiling point range of 350 to 650°C.

[0027] In an embodiment of the present invention, method 20 includes passing the top crude cut stream 104, the first stream 113 and / or the second stream 114 to the steam cracker 116 at block 207. At block 208, an embodiment of the present invention includes the steam cracker 116 processing the top crude cut stream 104, the first stream 113 and / or the second stream 114 to produce a high-value chemical stream 117, including olefins and / or aromatics. In an embodiment of the present invention, the olefins produced at block 208 include ethylene and propylene, and the aromatics include benzene. According to an embodiment of the present invention, the processing at block 208 includes operating the steam cracker 116 to produce propylene and ethylene, so that the mass ratio of propylene to ethylene (P / E) is 0.6 to 0.68. According to an embodiment of the present invention, the operating conditions providing a mass ratio of propylene to ethylene (P / E) of 0.6 to 0.68 include a temperature between 750 and 900°C and a pressure between <1atm and 3atmg.

[0028] Although the embodiments of the present invention have been described with reference to Figure 2 The blocks in FIG. 1 are described, but it should be understood that the operation of the present invention is not limited to Figure 2 Therefore, embodiments of the present invention may use different Figure 2 The various blocks in this order provide the functionality described herein.

[0029] The systems and processes described herein may also include various devices not shown, which are well known to those skilled in the art of chemical processing. For example, certain controllers, pipes, computers, valves, pumps, heaters, thermocouples, pressure indicators, mixers, heat exchangers, etc. may not be shown.

[0030] In the context of the present invention, at least the following 14 embodiments are disclosed. Embodiment 1 is a method for producing olefins and / or aromatics. The method includes flowing a hydrocarbon feed and hydrogen into a water treatment unit having a catalyst. The method also includes water treating the hydrocarbon feed in the water treatment unit to produce a first stream, including a gas having a boiling point below 200°C, producing a second stream having a boiling point between 200-350°C, and a third stream including one or more of asphalt, coke or fuel oil and having a boiling point between 350-650°C, wherein the water treatment of the hydrocarbon feed includes contacting the hydrocarbon feed and hydrogen with the catalyst in a temperature range of 400-500°C. The method also includes directing the first stream and the second stream to a steam cracking unit. In addition, the method also includes treating the first stream and the second stream in the steam cracking unit to produce olefins and / or aromatics, wherein the olefins include ethylene and propylene, and wherein the operation of the steam cracking unit causes the mass ratio (P / E) of propylene to ethylene to be 0.6 to 0.68. Embodiment 2 is the method of embodiment 1, wherein, in the water treatment unit, the contacting of the hydrocarbon feed and hydrogen with the catalyst is carried out in the reactor unit to produce a reactor unit effluent, and the method further includes separating the reactor unit effluent in a separation unit in the water treatment unit. Embodiment 3 is the method of embodiment 1, wherein the operating conditions of the steam cracking unit include a temperature of 750 to 900°C and a pressure of less than 1 atmosphere to 3 atmospheres. Embodiment 4 is the method of embodiment 1, wherein the water treatment unit includes: one or more of a fixed bed reactor, a boiling reactor, or a slurry reactor. Embodiment 5 is the method of embodiment 1, wherein the hydrocarbon feed includes one or more of the following (with or without water): crude oil, plastic, oligomers produced by pyrolysis of plastic, synthetic crude oil, bottom crude oil cut, bio-oil, and hydrocarbons produced by pyrolysis of plastic. Embodiment 6 is the method of embodiment 5, wherein the hydrocarbon feed includes a bottom crude oil cut stream, and the method further includes separating the crude oil in a separation device to produce a bottom crude oil cut stream and an upper crude oil cut stream having a boiling point in the range of up to 200°C. Embodiment 7 is the method of embodiment 6, further comprising treating the top crude cut stream in a steam cracker to produce olefins and / or aromatics. Embodiment 8 is the method of embodiment 1, wherein the catalyst comprises one or more of: an organometallic compound having one or more of Ni, Mo, Co, W, Zr; NiMo; NiCoMo; NiMoW; alumina; and zeolite.

[0031] Embodiment 9 is a system for producing olefins and / or aromatics. The system includes a water treatment unit in which a catalyst is disposed and is suitable for contacting a hydrocarbon feed and hydrogen with the catalyst in a temperature range of 400 to 500°C to produce a first stream containing a gas having a boiling point in the range of up to 200°C, a second stream having a boiling point in the range of 200 to 350°C, and a third stream containing one or more of asphalt, coke or fuel oil and having a boiling point in the range of 350 to 650°C. The method further includes a steam cracking unit in fluid communication with the water treatment unit, the steam cracking unit being suitable for producing olefins and / or aromatics from the first stream and the second stream. Embodiment 10 is the system of embodiment 9, wherein the water treatment unit includes one or more of a fixed bed reactor, a boiling reactor or a slurry reactor. Embodiment 11 is the system of embodiment 9, further comprising a separation device suitable for separating crude oil to produce at least a portion of a bottom crude oil cutting stream, the cutting stream being included in the hydrocarbons fed to the water treatment unit. Embodiment 12 is the system of embodiment 9, wherein the separation unit is in fluid communication with the steam cracking unit, and the system is adapted to flow a top crude oil cut stream having a boiling point in the range of up to 200° C. from the separation unit to the steam cracking unit. Embodiment 13 is the system of embodiment 9, wherein the water treatment unit is adapted to produce diesel. Embodiment 14 is the system of embodiment 9, wherein the water treatment unit comprises one or more distillation columns.

[0032] Unless explicitly excluded, all embodiments described above and herein can be combined in any way.

[0033] Although the embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions and modifications may be made herein without departing from the spirit and scope of the embodiments defined by the appended claims. In addition, the scope of the present application is not limited to the specific embodiments of the processes, machines, manufactures, material compositions, means, methods and steps described in the specification. As those of ordinary skill in the art will readily appreciate from the above disclosure, currently existing or later developed processes, machines, manufactures, material compositions, means, methods or steps may be used, which may perform substantially the same functions or achieve substantially the same results as the corresponding embodiments described herein. Therefore, the appended claims are intended to include such processes, machines, manufactures, material compositions, means, methods or steps within their scope.

Claims

1. A method for producing olefins and / or aromatics, the method comprising: flowing a hydrocarbon feed and hydrogen into a water treatment unit having a catalyst disposed therein; The hydrocarbon feed is subjected to water treatment in the water treatment unit to produce a first stream comprising gas having a boiling point in the range of 200° C., a second stream having a boiling point in the range of 200 to 350° C., and a third stream comprising one or more of asphalt, coke or fuel oil and having a boiling point in the range of 350 to 650° C.; wherein the water treatment of the hydrocarbon feed comprises contacting the hydrocarbon feed and hydrogen with the catalyst at a temperature in the range of 400 to 500° C.; passing the first stream and the second stream into a steam cracking unit; and The first and second streams are processed in the steam cracking unit to produce olefins and / or aromatics, wherein the olefins include ethylene and propylene, wherein the steam cracking unit is operated such that the mass ratio of propylene to ethylene (P / E) is from 0.6 to 0.

68.

2. The method according to claim 1, wherein: within the water treatment unit, contacting the hydrocarbon feed and the hydrogen with the catalyst is conducted in a reactor unit to produce a reactor unit effluent; And the method also includes: The reactor unit effluent is separated in a separation unit within the water treatment unit.

3. The method according to claim 1, wherein: The operating conditions of the steam cracking unit are 750-900° C. and pressure <1 atm-3 atmg.

4. The method according to claim 1, wherein: The water treatment unit comprises one or more of the following: a fixed bed reactor, a boiling reactor or a slurry reactor.

5. The method of claim 1, wherein the hydrocarbon feed comprises one or more of the following: crude oil, plastic, oligomers from plastic pyrolysis, synthetic crude oil, bottom crude oil fraction, bio-oil, synthetic crude oil, and hydrocarbons from plastic pyrolysis.

6. The method according to claim 5, wherein: The hydrocarbon feed comprises a bottoms crude oil fraction stream, and the method further comprises: The crude oil is separated in a separation unit to produce said bottom crude oil fraction stream and a top crude oil fraction stream having a boiling point in the range of up to 200°C.

7. The method according to claim 6, further comprising: The overhead crude fraction stream is processed in the steam cracking unit to produce olefins and / or aromatics.

8. The method according to claim 1, wherein: The catalyst includes one or more of the following: an organometallic compound having one or more of Ni, Mo, Co, W, Zr; NiMo; NiCoMo; NiMoW; alumina; and zeolite.

9. A system for producing olefins and / or aromatics, the system comprising: a water treatment unit having a catalyst disposed therein and adapted to contact a hydrocarbon feed and hydrogen with the catalyst at a temperature of 400 to 500° C. to produce a first stream comprising a gas having a boiling point up to 200° C., a second stream having a boiling point of 200 to 350° C., and a third stream comprising one or more of asphalt, coke, or fuel oil and having a boiling point of 350 to 650° C.; and A steam cracking unit is in fluid communication with the water treatment unit, the steam cracking unit being adapted to produce olefins and / or aromatics from the first stream and the second stream.

10. The system according to claim 9, wherein: The water treatment unit includes one or more of the following: a fixed bed reactor, a boiling reactor or a slurry reactor.

11. The system of claim 9, further comprising: A separation unit adapted to separate crude oil to produce at least a portion of a bottoms crude fraction stream contained in the hydrocarbon feed to the water treatment unit.

12. The system according to claim 11, wherein: The separation unit is in fluid communication with the steam cracking unit, and the system is adapted to flow an overhead crude oil fraction stream having a boiling point in the range of up to 200°C from the separation unit to the steam cracking unit.

13. The system according to claim 9, wherein: The water treatment unit is suitable for producing diesel.

14. The system according to claim 9, wherein: The water treatment unit comprises one or more distillation columns.

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