Water treatment of crude oil and heavy hydrocarbon feedstocks

Abstract

A system and method for producing diesel and / or fuel oil products using hydrocarbon feedstocks is disclosed. The system includes a water treatment unit in fluid communication with the vacuum distillation apparatus and treats vacuum residues under conditions to produce diesel and fuel oil.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] none. Technical Field

[0002] The present invention generally relates to systems and methods for producing diesel and low sulfur fuel oil or lubricating oil products from hydrocarbon feedstocks while also producing high value chemical products. The system may include a water treatment unit coupled to a crude distillation unit (CDU) and / or a vacuum distillation unit (VDU), wherein a vacuum residue (VR) from the vacuum distillation unit is fed to the water treatment unit and treated under certain conditions to produce diesel, fuel oil and / or asphalt. According to the method of the present invention, the vacuum residue is fed to the water treatment unit and water treated under conditions to produce diesel, fuel oil and / or asphalt. In addition, pyrolysis oil can also be fed to the water treatment unit and water treated together with the VR to produce desirable products such as diesel and fuel oil. If necessary, the diesel and / or fuel oil will be hydrotreated to remove the sulfur content to a desired level to meet commercial needs, such as meeting European diesel or very low sulfur fuel oil specifications. Background Art

[0003] Diesel fuel is an important fuel for the automotive and trucking industries. Fuel oil is an important heating fuel for commercial and residential use. Both diesel and fuel oil are produced from crude oil, which may contain sulfur. Sulfur promotes oxidation of the fuel, which can lead to emissions that pollute the environment, which is undesirable. To meet emission standards, diesel and fuel oil should have a low sulfur content to reduce pollution and meet current standards. Typically, sulfur is removed by hydrotreating.

[0004] Typically, diesel and heating oil are produced by subjecting various heavier crude oil cuts, such as vacuum residue, to catalytic hydrocracking processes. These hydrocracking processes are energy intensive and do not always provide adequate product yields. As demand for diesel and fuel oil products grows, more efficient systems and processes are needed to produce diesel and fuel oil products. Summary of the invention

[0005] It has been discovered that a solution is provided to at least one problem associated with diesel and / or fuel oil production.

[0006] In one aspect, the discovery may include a system that provides a water treatment unit fluidly connected to the VDU for receiving the vacuum residue and treating it under conditions suitable for producing diesel and / or fuel oil. The water treatment unit may also have an inlet for receiving pyrolysis oil for processing in conjunction with or in place of the VR. Such an apparatus may reduce the costs associated with the use of currently used crackers and may also reduce the energy required to produce diesel and fuel oil. The water treatment is the hydrocracking of hydrocarbons under the following conditions: (a) one or more catalysts; (b) a solvent that keeps asphaltenes dissolved, at a temperature between 280 and 550°C and a pressure between 40 and 200 barg. In an embodiment of the present invention, the water treatment conditions may include a hydrogen to hydrocarbon ratio of 200 to 2000NL / L in the liquid feed, and the water treatment may be carried out with or without the addition of steam.

[0007] One aspect of the present invention describes a process for producing diesel and / or fuel oil products. One process involves producing low-sulfur diesel. The process includes the following steps: flowing a hydrocarbon feed into a water treatment unit having a water treatment catalyst disposed therein; contacting the hydrocarbon feed with a first catalyst in a temperature range of 275 to 400°C to produce a water treatment effluent having a boiling point of 35 to 650°C; separating the water treatment effluent to form a first stream comprising a hydrocarbon fraction having a boiling point below 305°C and a second stream comprising a hydrocarbon fraction having a boiling point above 305°C, wherein the second stream comprises diesel; and hydrotreating the second stream to remove sulfur to produce a hydrotreated second stream comprising low-sulfur diesel having a sulfur content of 0 ppm to 50 ppm.

[0008] One aspect of the present invention relates to a process for producing very low sulfur fuel oil, the method comprising the following steps: flowing a hydrocarbon feed into a water treatment device having a water treatment catalyst; contacting the hydrocarbon feed with a first catalyst at a temperature in the range of 275 to 400°C to produce a water treatment effluent; separating the water treatment effluent to form a first stream comprising a hydrocarbon fraction having a boiling point below 350°C and a second stream comprising a hydrocarbon fraction having a boiling point above 350°C, wherein the second stream comprises fuel oil having a boiling point above 350 to 600°C; and hydrotreating the second stream to remove sulfur to produce a hydrotreated second stream comprising very low sulfur fuel oil having a sulfur content of 0 to 50 ppm.

[0009] One aspect of the present invention relates to a process for steam cracking a feed produced by a water treatment process. The process comprises the following steps: flowing a hydrocarbon feed into a water treatment device in which a water treatment catalyst is disposed; contacting the hydrocarbon feed with a first catalyst at a temperature in the range of 275 to 400° C. to produce a water treatment effluent having a boiling point in the range of 35° C. to 400° C.; and feeding at least a first fraction of the water treatment effluent to a steam cracking device, and steam cracking the first fraction to produce olefins.

[0010] One aspect of the present invention relates to a process for processing a hydrocarbon feed, wherein the process comprises the following steps: flowing the hydrocarbon feed into a water treatment unit, wherein a water treatment catalyst is disposed in the unit, wherein the hydrocarbon feed is a heavy feed having a boiling point greater than 275 to 900° C., preferably 275 to 400° C., or preferably 500 to 900° C.; contacting the hydrocarbon feed with a first catalyst within a temperature range of 275 to 400° C. to produce a water treatment effluent having a boiling point between 35 and 400° C.; separating the water treatment effluent to form a first light stream (including a hydrocarbon fraction having a boiling point between 25 and 300° C.), a first heavy stream (including a hydrocarbon fraction having a boiling point greater than 300° C.), and a second heavy stream (including a hydrocarbon fraction having a boiling point greater than 300° C.). ℃ hydrocarbon fraction) and a gaseous stream; separating the first light gas stream into a second light stream with a boiling point between 70 and 140℃ and a remaining light stream; sending the second light stream to a catalytic naphtha converter, which includes a second catalyst, and the second light stream contacts the second catalyst at a temperature of 35 to 400℃ under conditions for producing aromatics to produce an effluent; sending the remaining light fraction to a first steam cracker or a first catalytic naphtha cracker including a fourth catalyst; wherein the first heavy stream is recycled to a water treatment unit, or the first heavy stream is saturated by hydrogenation with hydrogen and sent to the first steam cracker or a catalytic cracking unit including a fifth catalyst.

[0011] Other embodiments of the present invention are also discussed in this application.Any embodiment discussed with regard to one aspect of the present invention is also applicable to other aspects of the present invention, and vice versa.Each embodiment described herein is understood to be an embodiment of the present invention applicable to other aspects of the present invention.It can be believed that any embodiment or aspect discussed herein can be combined with other embodiments or aspects discussed herein and / or implemented with any method or composition of the present invention, and vice versa.In addition, composition of the present invention can be used to realize method of the present invention.

[0012] The following include definitions of various terms and phrases used throughout this specification.

[0013] The term "C# hydrocarbons" (where "#" is a positive integer) refers to all hydrocarbons with # carbon atoms. Additionally, the term "C#+ hydrocarbons" refers to all hydrocarbon molecules with # or more carbon atoms. Thus, the term "C9+ hydrocarbons" refers to a mixture of hydrocarbons with 9 or more carbon atoms.

[0014] "Water treatment" refers to hydrocracking hydrocarbons in the presence of (a) one or more water treatment catalysts and (b) a solvent that keeps asphaltenes dissolved, at a temperature of 280 to 550°C and a pressure range of 40 to 200 barg. In embodiments of the present invention, the water treatment conditions may include a hydrogen-to-hydrocarbon ratio of 200 to 2000 NL / L in the liquid feed, and the water treatment may be performed with or without the addition of steam.

[0015] "Hydrocarbons" are generally defined as molecules composed primarily of carbon and hydrogen atoms. Hydrocarbons may also include other elements, such as, but not limited to, halogens, metallic elements, nitrogen, oxygen, and / or sulfur. Hydrocarbon fluids may include, entrain, or be entrained in non-hydrocarbon fluids such as hydrogen, nitrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, water, and / or ammonia.

[0016] 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, the term "about" or "approximately" is defined as within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

[0017] The terms "wt. %, "vol. %" or "mol. %" refer to the weight percentage, volume percentage or mole percentage of a component based on the total weight, total volume or total moles of the material including the component, respectively. In a non-limiting example, 100 grams of a component in 100 grams of material is 10 wt. % of the component.

[0018] The term "substantially" and variations thereof are defined to include ranges within 10%, within 5%, within 1%, or within 0.5%.

[0019] 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 result.

[0020] The term "effective" as used in the specification and / or claims means sufficient to achieve an intended, desired, or purposeful result.

[0021] "A" or "an" used in conjunction with any term "comprising," "including," "containing," or "having" in the claims or description may mean "one," but also have the meaning of "one or more," "at least one," and "one or more."

[0022] The words "comprise" (and any forms of inclusion, such as "have" and "include"), "have" (and any forms of having, such as "contain" and "include"), "contain" (and any forms of containing, such as "include" and "include"), or "includes" (and any forms of inclusion, such as "including" and "having") are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0023] The systems and processes of the present invention may "comprise," "consist essentially of," or "consist of" specific ingredients, components, compositions, etc. disclosed throughout the specification. With respect to the transitional phrase "consisting essentially of," in one non-limiting aspect, a fundamental and novel feature of the systems and methods of the present invention is their ability to produce olefin products (e.g., ethylene) in a cost and energy efficient manner by having an ethane steam cracking unit capable of receiving ethane from a mixed feed steam cracking unit and delivering C2+ products produced by the ethane steam cracking unit to the mixed feed steam cracking unit.

[0024] 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 although these figures, detailed descriptions and examples show specific embodiments of the present invention, they are provided for illustration only and are not meant to be restrictive. In addition, changes and modifications within the spirit and scope of the present invention are also 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 an embodiment may be combined with the features of any other embodiment. In more embodiments, the specific embodiments described herein may also add other features. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Advantages of the present invention will become apparent to those skilled in the art from the following detailed description with reference to the accompanying drawings.

[0026] Figure 1 An embodiment of a system for producing a diesel and / or fuel oil product from a hydrocarbon feed provided to a water treatment unit is shown.

[0027] Figure 2 Examples of systems for producing diesel and / or fuel oil products from hydrocarbon feeds provided to a water treatment unit and other methods operating with the systems to produce additional hydrocarbon products are shown.

[0028] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings. The drawings may not be drawn to scale. DETAILED DESCRIPTION

[0029] A discovery provides a solution to at least one of the problems associated with steam cracking a mixed hydrocarbon feed. In one aspect, the mixed hydrocarbon feed can be fed to a mixed hydrocarbon steam cracking unit to produce petroleum products and ethane. The ethane can be provided to a separate ethane cracking unit to produce ethylene and / or a C2+ hydrocarbon stream that can be recycled to the mixed hydrocarbon steam cracking unit. An advantage of such a unit is that the mixed hydrocarbon steam cracking unit can perform C2+ cracking under optimal conditions, while the ethane steam cracking unit can perform ethane cracking under optimal conditions. These and other non-limiting aspects of the invention will be discussed in further detail in the following sections with reference to the accompanying drawings.

[0030] refer to Figure 1 , describes a system 100 for producing diesel and / or fuel oil products. The system 100 may include a vacuum distillation unit 102, a water treatment unit 104, and a hot hydroprocessing gas (DPHG) unit 106. A hydrocarbon feed 108 enters the vacuum distillation unit 102 and is separated into various heavy and light fractions, the heaviest of which is the vacuum residue, which is sent to the water treatment unit 104. The hydrocarbon feed is typically crude oil and may be first processed in a crude distillation unit (CDU).

[0031] Crude oil can be unrefined petroleum extracted from geological formations. The term crude oil also includes oil that has been treated with water-oil separation and / or gas-oil separation and / or desalting and / or stabilization. Non-limiting examples of crude oil include Arab heavy crude oil, Arab light crude oil, other Gulf crude oil, Brent crude oil, North Sea crude oil, North African and West African crude oil, Indonesian crude oil, Chinese crude oil, West Texas crude oil and mixtures thereof, as well as shale oil, pyrolysis oil sands, natural gas condensate and bio-based oil. The crude oil used as feed for the process of the present invention is preferably conventional oil with an API gravity greater than 20°API as measured by ASTM D287 standard. On the one hand, the crude oil used in the process of the present invention is a light crude oil with an API gravity greater than 30°API. On the other hand, the crude oil used in the process of the present invention can include Arab light crude oil. The API gravity of Arab light crude oil is generally between 32-36°API, and the sulfur content is between 1.5-4.5wt.%.

[0032] In certain aspects, the vacuum residue may be subjected to a solvent deasphalting step to remove asphaltenes prior to being sent to a water treatment unit.

[0033] The feed 108 may include other hydrocarbons, including plastics, oligomers produced by pyrolysis of plastics, synthetic crude oils or hydrocarbons produced by pyrolysis of plastics, or any combination of these substances, which can be co-processed with the crude oil feed in the aquaculture processing unit 104.

[0034] In the water treatment unit 104, the vacuum residue and / or other hydrocarbon feed can be subjected to water treatment under conditions sufficient to produce diesel 112 and / or fuel oil 114. In a preferred aspect, the conditions are sufficient to produce diesel. In one aspect, the conditions are suitable for producing fuel oil.

[0035] The vacuum residue 110 may flow from the vacuum distillation device 102 to the water treatment unit 104. In the water treatment unit 104, the vacuum residue and optional pyrolysis oil 118 are subjected to water treatment in the presence of a water treatment catalyst at a temperature of 275° C. to 400° C. (e.g., 300° C., 325° C., 350° C., 375° C., 400° C., or any value or range therebetween) to produce a water treatment effluent. At such a temperature and pressure, the vacuum residue is not completely cracked, thereby producing more diesel and / or fuel oil products.

[0036] refer to Figure 2 , depicts a system 200 for producing diesel and / or fuel oil products. The system 200 may include a vacuum distillation unit 202, a water treatment unit 204, and a DPHG unit 206. A hydrocarbon feed 208 enters the vacuum distillation unit 202 and is separated into various heavy and light fractions, including a VDU light fraction 209, a VDU naphtha stream 211, the heaviest of which is a vacuum residue 210, which is sent to the water treatment unit 204. The hydrocarbon feed is typically crude oil and may be first processed in a crude distillation unit (CDU).

[0037] In certain aspects, the vacuum residue may be subjected to a solvent deasphalting step to remove asphaltenes prior to being sent to a water treatment unit, or in a water treatment unit.

[0038] The feed 208 may include other hydrocarbons, including plastics, oligomers produced by pyrolysis of plastics, synthetic crude oils or hydrocarbons produced by pyrolysis of plastics, or any combination of these substances, which can be co-processed with the crude oil feed in the water treatment unit 204.

[0039] In the water treatment unit 204, the vacuum residue and / or other hydrocarbon feeds can be water treated under conditions sufficient to produce diesel 212 and a water treated naphtha stream 203, a light stream 205, and a very low sulfur fuel oil and / or asphalt stream 207. In a preferred aspect, the conditions are sufficient to produce diesel. In one aspect, the conditions are suitable for producing fuel oil.

[0040] The vacuum residue 210 may flow out of the vacuum distillation unit 202 and enter the water treatment unit 20404. In the water treatment unit 204, the vacuum residue and optional pyrolysis oil 218 are subjected to water treatment at a temperature of 275° C. to 400° C. (e.g., 300° C., 325° C., 350° C., 375° C., 400° C., or any value or range therebetween) and / or at an appropriate pressure. At such a temperature and pressure, the vacuum residue is not completely cracked, thereby producing more diesel and / or fuel oil products.

[0041] The VDU naphtha stream 211 is fed into the steam cracking furnace 220 , and the water-treated naphtha stream 203 is fed into the steam cracking furnace 220 or mixed with the VDU naphtha stream 211 to form a mixed naphtha stream 221 which is fed into the steam cracking furnace 220 .

[0042] The VDU light oil stream 209 and the water treatment light oil stream 205 are sent to the gas device 222 and react under certain conditions to produce a gas device light oil stream 251 and fuel gas 223.

[0043] The phosgene stream 221 of the gasification unit enters the steam cracking unit 220, and reacts with the naphtha stream 221 (or the separate VDU naphtha stream 221 and the water-treated naphtha stream 203) under certain conditions to generate a hydrogen stream 253, an ethylene stream 224, a propylene stream 225, and a raw C4 stream 226. The steam cracking unit 220 also generates a char stream 227, which is transported to the DPHG unit 206, where it is treated to generate a bottom C9+ stream 228 and a C6-C8 hydrocarbon stream 229, which is transported to the BTX extraction unit 230. The BTX extraction unit separates various BTX components into a xylene stream 231, a benzene stream 232, and a toluene stream 233, which are recovered as products. The BTX extraction unit also generates a C5-C8 gas stream 252, which is sent to the steam cracker 220 for steam cracking.

[0044] The bottom C9+ stream 228 is mixed with the steam cracked C9+ stream 234 from the steam cracking unit 220 to form the pyrolysis oil stream 218 and is sent back to the water treatment unit 204 for further water treatment.

[0045] Various aspects of the present invention provide a process for producing low-sulfur diesel, the method comprising: flowing a hydrocarbon feed into a water treatment device in which a water treatment catalyst is disposed; contacting the hydrocarbon feed with the water treatment catalyst at a temperature in the range of 275 to 400°C to produce a water treatment effluent; separating the water treatment effluent to form a first stream including a hydrocarbon fraction having a boiling point below 305°C and a second stream including a hydrocarbon fraction having a boiling point above 305°C, wherein the second stream includes diesel; and hydrotreating the second stream to remove sulfur to produce a hydrotreated second stream including low-sulfur diesel having a sulfur content of 0 to 50 ppm. The second gas stream may further include an ultra-low sulfur fuel oil having a sulfur content of 0 to 50 ppm. The process also includes the step of treating crude oil in a vacuum distillation device to produce a vacuum distillation residue; wherein the hydrocarbon feed includes a vacuum distillation residue. The process may also include the following steps: separating the vacuum distillation product into a light vacuum distillation fraction having a boiling point in the range of 35 to 400°C, a heavy vacuum distillation fraction having a boiling point range higher than the light vacuum distillation fraction, and a naphtha fraction having a boiling point in the range of 35 to 400°C; feeding the heavy vacuum distillation fraction from the bottom of the vacuum distillation device into a water treatment device. The process may further include feeding the second stream into a steam cracking device; and steam cracking the second stream to produce olefins. The process may also optionally include the step of feeding steam into a first water treatment unit. The first water treatment unit includes a fixed bed reactor. The first catalyst is selected from

[0046] In certain aspects, the present invention relates to a process for producing very low sulfur fuel oil, comprising the steps of: passing a hydrocarbon feed into a water treatment unit in which a water treatment catalyst is disposed; contacting the hydrocarbon feed with a first catalyst at a temperature in the range of 275 to 400°C to produce a water treatment effluent; separating the water treatment effluent to form a first stream comprising a hydrocarbon fraction having a boiling point below 350°C and a second stream comprising a hydrocarbon fraction having a boiling point above 350°C, wherein the second stream comprises fuel oil; hydrotreating the second stream to remove sulfur, thereby producing a hydrotreated second stream comprising very low sulfur fuel oil having a sulfur content of 0 to 50 ppm. The process may further comprise the steps of: passing the second stream into a steam cracking unit; steam cracking the second stream to produce olefins. The process may also optionally comprise the step of passing steam into a first water treatment unit. The first water treatment unit comprises a fixed bed reactor. The water treatment catalyst may comprise a dissolved portion and a dispersed portion. The dissolved portion of the catalyst comprises an organometallic compound having one or more of Ni, Mo, Co, W, and Zr. The dissolved portion of the catalyst may include metal naphthenates and / or octoates having hydrogenation activity. The dispersed portion of the catalyst may be selected from the following list: alkali metal hydroxides or oxides, Ni-Mo oxides or sulfides, Co-Mo oxides or sulfides, W-Mo oxides or sulfides on alumina or zeolites, or any combination of these materials having hydroprocessing and / or hydrogen transfer activity.

[0047] Various aspects also relate to a process for steam cracking a feed produced by a water treatment process, comprising the steps of: flowing a hydrocarbon feed into a water treatment device having a water treatment catalyst disposed therein; contacting the hydrocarbon feed with a first catalyst at a temperature in the range of 275 to 400° C. to produce a water treatment effluent having a boiling point in the range of 35 to 400° C.; and feeding at least a first fraction of the water treatment effluent to a steam cracker, and steam cracking the first fraction to produce olefins.

[0048] Any of the above processes can add pyrolysis oil to the hydrocarbon feed of the water treatment unit, or provide pyrolysis oil separately through a suitable inlet. Pyrolysis oil can come from an additional process in the system. For example, pyrolysis oil is produced in a hot gas hydrotreater (DPHG).

[0049] In certain aspects, any of the processes described herein may include one or more of the following in the hydrocarbon feed: crude oil, plastics, oligomers from plastic pyrolysis, synthetic crude oil, crude oil cuts, and hydrocarbons from plastic pyrolysis. These materials may be in addition to or as a substitute for vacuum residue and / or pyrolysis oil.

[0050] Aspects also relate to a process for treating a hydrocarbon feed, the process comprising the steps of flowing the hydrocarbon feed into a water treatment having a water treatment catalyst, wherein the hydrocarbon feed is an optional vacuum residue; contacting the hydrocarbon feed with a first catalyst at a temperature in the range of 275 to 400°C to produce a water treatment effluent having a boiling point of 35 to 650°C; separating the water treatment effluent to form a first light stream (including a hydrocarbon fraction having a boiling point of 25 to 305°C), a first heavy stream (including a hydrocarbon fraction having a boiling point greater than 305°C), and a gaseous stream; separating the first light stream into a first heavy stream having a boiling point between 70 and 140°C; The second light stream and the remaining light fraction; the second light gas stream is sent to a catalytic naphtha converter, which includes a second catalyst, and aromatics are produced by contacting the second light gas stream with the second catalyst at a certain temperature under conditions of producing aromatics; the remaining light fraction is sent to a first steam cracker including a steam cracking catalyst or a first catalytic naphtha cracker including a fourth catalyst at a temperature of 350 to 900°C; wherein the first heavy oil stream is recovered to the first water treatment unit, or the first heavy oil stream is saturated by hydrogenation and sent to the first steam cracking unit or a catalytic cracking unit including a fifth catalyst. The gaseous stream is sent to the steam cracking unit. The gaseous liquid stream can also be separated into an ethane stream, a butane stream and a propane stream.

[0051] Non-limiting examples of the present invention will now be described. Example 1 is a process for producing low-sulfur diesel, the process comprising the steps of flowing a hydrocarbon feed into a water treatment device in which a water treatment catalyst is disposed; contacting the hydrocarbon feed with a first catalyst at a temperature in the range of 275 to 400°C to produce a water treatment effluent having a boiling point range of 35 to 650°C; separating the water treatment effluent to form a first stream comprising a hydrocarbon fraction having a boiling point lower than 305°C and a second stream comprising a hydrocarbon fraction having a boiling point higher than 305°C, wherein the second stream comprises diesel; and hydrotreating the second stream to remove sulfur to produce a hydrotreated second stream comprising low-sulfur diesel having a sulfur content of 0 to 50 ppm. Example 2 is the process of Example 1, wherein the second stream further comprises an ultra-low sulfur fuel oil having a sulfur content of 0 to 50 ppm. Example 3 is the process of Example 1, wherein the process further comprises the step of treating crude oil in a vacuum distillation device to produce a vacuum distillation residue; wherein the hydrocarbon feed comprises a vacuum distillation residue. Embodiment 4 is the process of embodiment 3, further comprising the steps of: separating the vacuum distillation product into a light vacuum distillation fraction, a heavy vacuum distillation fraction having a boiling point higher than the light vacuum distillation fraction, and a naphtha range fraction; and feeding the heavy vacuum distillation fraction from the bottom of the vacuum distillation unit to a water treatment unit. Embodiment 5 is the process of embodiment 1, further comprising the steps of: feeding the second gas stream to a steam cracking unit; and steam cracking the second gas stream to produce olefins. Embodiment 6 is the process of embodiment 1, further comprising the step of feeding steam to the first water treatment unit. Embodiment 7 is the process of embodiment 1, wherein the first water treatment unit comprises a fixed bed reactor. Embodiment 8 is the process of embodiment 1, wherein the first catalyst comprises a particulate catalyst and a dissolved catalyst, preferably, wherein the dissolved catalyst comprises an organometallic compound having one or more of Ni, Mo, Co, W, Zr, preferably in the form of a metal naphthenate and / or octanoate, and / or wherein the dispersed portion of the catalyst is selected from the following list: alkali metal hydroxides or oxides, Ni-Mo oxides, Ni-Mo sulfides, Co-Mo oxides or Co-Mo sulfides, W-Mo oxides, W-Mo sulfides, preferably on alumina or zeolites, or any combination of these. Example 9 is a process for producing ultra-low sulfur fuel oil, which includes the following steps: flowing a hydrocarbon feed into a water treatment device in which a water treatment catalyst is disposed; contacting the hydrocarbon feed with a first catalyst in a temperature range of 275 to 400°C to produce a water treatment effluent; separating the water treatment effluent to form a first stream containing a hydrocarbon fraction having a boiling point lower than 350°C and a second stream containing a hydrocarbon fraction having a boiling point higher than 350°C, wherein the second stream contains fuel oil; and hydrotreating the second stream to remove sulfur to produce a hydrotreated second stream containing ultra-low sulfur fuel oil having a sulfur content of 0 to 50 ppm.Embodiment 10 is the process of embodiment 9, further comprising the steps of: feeding the second stream to a steam cracking unit; and steam cracking the second stream to produce olefins. Embodiment 11 is the process of embodiment 1, further comprising the step of flowing steam into the first water treatment unit. Embodiment 12 is the process of embodiment 9, wherein the first water treatment unit comprises a fixed bed reactor. Embodiment 13 is the process of embodiment 9, wherein the first catalyst comprises a particulate catalyst and a dissolved catalyst, preferably, wherein the dissolved catalyst comprises an organometallic compound having one or more of Ni, Mo, Co, W, Zr, preferably in the form of a metal naphthenate and / or octanoate, and / or wherein the dispersed portion of the catalyst is selected from the following list: alkali metal hydroxides or oxides, Ni-Mo oxides, Ni-Mo sulfides, Co-Mo oxides or Co-Mo sulfides, W-Mo oxides, W-Mo sulfides, preferably on alumina or zeolites, or any combination of these. Embodiment 14 is a process for steam cracking a feed produced by a water treatment process, the process comprising the steps of: flowing a hydrocarbon feed into a water treatment unit having a water treatment catalyst; contacting the hydrocarbon feed with a first catalyst at a temperature in the range of 275 to 400°C to produce a water treatment effluent having a boiling point in the range of 35°C to 400°C; and feeding at least a first fraction of the water treatment effluent to a steam cracker, and steam cracking the first fraction to produce olefins. Embodiment 15 is the process of any of the preceding embodiments, wherein the hydrocarbon feed further contains pyrolysis oil. Embodiment 16 is the process of embodiment 15, wherein pyrolysis oil is produced in a DPHG unit. Embodiment 17 is the process of any of the preceding embodiments, wherein the hydrocarbon feed comprises one or more of: crude oil, plastics, oligomers produced by pyrolysis of plastics, synthetic crude oil, crude oil cuts, and hydrocarbons produced by pyrolysis of plastics.Embodiment 18 is a process for treating a hydrocarbon feed, the process comprising the following steps: flowing the hydrocarbon feed into a water treatment device in which a first catalyst is disposed, wherein the hydrocarbon feed is a heavy feed from a vacuum distillation device; contacting the hydrocarbon feed with the first catalyst at a temperature in the range of 275 to 400° C. to produce a water treatment effluent having a boiling point of 35 to 650° C.; separating the water treatment effluent to form a first light stream comprising a hydrocarbon fraction having a boiling point of 25 to 300° C., a first light stream comprising a hydrocarbon fraction having a boiling point of more than 300° C., and a second light stream comprising a hydrocarbon fraction having a boiling point of more than 300° C. A heavy stream and a gaseous stream; separating the first light stream into a second light stream having a boiling point between 70 and 140°C and a remaining light stream; sending the second light stream to a catalytic naphtha converter containing a second catalyst to produce aromatics by contacting the second light stream with the second catalyst; sending the remaining light fraction to a first steam cracking unit or a first catalytic naphtha cracking unit containing a naphtha catalytic cracking catalyst; wherein the first heavy stream is recycled to a first water treatment unit, or wherein the first heavy stream is saturated by hydrogenation with hydrogen and sent to a first steam cracking unit or a catalytic cracking unit containing a fifth catalyst. Example 19 is the process of Example 18, wherein the gaseous stream is sent to a steam cracking unit. Example 20 is the process of Example 18, wherein the gaseous stream is separated into a gaseous stream containing ethane, a gaseous stream containing butane, and a gaseous stream containing propane. Example 21 is a process for co-producing diesel, lubricating oil base oil and high-value chemicals in an integrated plant from petroleum to chemicals, the process comprising the following steps: passing a hydrocarbon feed stream to a separation device to produce a first light stream and a heavy stream; passing the heavy stream to a water treatment device in which a water treatment catalyst is disposed; contacting the heavy stream with the water treatment catalyst at a temperature in the range of 275 to 400° C. to produce a water treatment effluent having a boiling point in the range of 35 to 650° C.; separating the water treatment effluent to form a hydrocarbon fraction containing a boiling point below 305° C. A first water treatment stream, a second water treatment stream containing a hydrocarbon fraction with a boiling point between 305 and 370°C, and a third water treatment stream with a boiling point above 370°C, wherein the second water treatment stream contains diesel; the second water treatment stream is selectively hydrotreated to remove sulfur, thereby producing a second water treatment stream after hydrotreatment, which contains low-sulfur diesel with a sulfur content of less than 50 ppm; the third water treatment stream is sent to a hydroisomerization and cracking unit to produce lubricating oil base oil; the light stream and the first water treatment stream are sent to a steam cracking unit to produce olefins and residual pyrolysis oil. Example 22 is a process according to Example 21, wherein the light oil stream is sent to a gas unit and a VDU naphtha stream with a boiling point of up to 220°C is sent to a steam cracking unit.Embodiment 23 is a process according to embodiment 22, wherein the light stream is fed to a gas unit, the gas unit separates the light bodies into a condensed naphtha gas stream, the condensed naphtha gas stream is fed to a steam cracker, the gas unit gas stream is selectively separated into ethane and liquefied petroleum gas, ethane is selectively fed to an ethane cracker, and the liquefied petroleum gas is selectively fed to a liquefied petroleum gas steam cracker. Embodiment 24 is a process according to embodiment 22, wherein the light stream is fed to a gas unit, the gas unit separates the light gases into a condensed naphtha gas stream and a gas stream, the condensed naphtha gas stream is further fed to a naphtha steam cracker, the gas stream is further separated into ethane, propane and butane, ethane, propane and butane are respectively fed to an ethane cracker, a propane cracker or a propane dehydrogenation unit, and the butane cracking charge stream is further separated to produce a gas effluent, the gas effluent is fed to the gas unit, and optionally a residual liquid effluent is produced, the liquid effluent is fed to a naphtha steam cracker. Embodiment 25 is a process according to embodiment 21, wherein the first stream is further separated to produce a gaseous effluent, which is sent to a gas unit, and the remaining liquid effluent is optionally sent to a naphtha steam cracker. Embodiment 26 is a process according to embodiment 21, wherein the third stream is recovered as a fuel oil gas stream. Example 27 is a process for co-producing diesel and high-value chemicals in a petroleum-to-chemicals integrated unit, the process comprising the following steps: passing a hydrocarbon feed stream to a separation unit to separate it into a light component and a heavy component; sending the heavy component to a water treatment unit in which a water treatment catalyst is disposed; contacting the heavy component with the water treatment catalyst in a temperature range of 275 to 400°C to produce a water treatment effluent with a boiling point range of 35 to 650°C; separating the water treatment effluent to form a first stream containing a hydrocarbon fraction with a boiling point below 305°C and a second stream containing a hydrocarbon fraction with a boiling point above 305°C, wherein the second stream is sent to a catalytic cracking unit to produce high-value chemicals, saturated gas and residual liquid; sending the light cut material and the first stream to a steam cracking unit to produce high-value chemicals and residual pyrolysis oil; and recovering the residual liquid and the residual pyrolysis oil to the water treatment unit. Embodiment 28 is a process according to embodiment 27, wherein the light cut comprises a light gaseous stream fed to a gas plant and saturated gas from a catalytic cracking unit, and a residual naphtha stream having a boiling point of up to 220° C. fed to a steam cracking unit. Embodiment 29 is a process according to embodiment 27, wherein the light gaseous stream is fed to a gas plant, the gas plant separates the light gas into a condensed naphtha stream, the condensed naphtha stream is further fed to a steam cracking unit, and the gas stream is further separated into ethane and LPG, and fed to ethane and LPG steam cracking units, respectively.Embodiment 30 is a process according to embodiment 28, wherein the light gaseous stream is fed to a gas unit, the gas unit separates the light gas into a condensed naphtha stream, the condensed naphtha stream is further fed to a naphtha steam cracking unit, the gas stream is further separated into ethane, propane and butane, the ethane, propane and butane are fed to an ethane cracking unit, a propane cracking unit or a propane dehydrogenation unit, a butane cracking unit or a butane dehydrogenation unit. Embodiment 31 is a process according to embodiment 27, wherein the first stream is divided into a gaseous effluent, the gaseous effluent is fed to a gas unit, and optionally, the remaining liquid effluent is fed to a naphtha steam cracking unit. Embodiment 32 is an embodiment according to embodiments 21 and 27, wherein the first stream produces a 70-140°C fraction and a light liquid stream after splitting. Embodiment 33 is a process according to embodiment 32, wherein 70-140°C is fed to a catalytic naphtha reformer to produce BTX aromatics, and the saturated gas stream is sent to a general gas plant non-aromatic liquid stream. Embodiment 34 is a process according to embodiment 32, wherein the remaining light liquid and non-aromatic liquid stream is sent to a naphtha steam cracking furnace. Embodiment 35 is a process according to any of the preceding embodiments, wherein the hydrocarbon feed is selected from crude oil, hydrogenated bio-oil, oligomers extracted from plastic synthetic crude oil and plastic pyrolysis oil, unconverted oil from refineries, pyrolysis oil and heavy slag from steam cracking furnaces. Embodiment 36 is a process according to embodiment 21 or 27, wherein the heavy fraction is sent to a water treatment unit and mixed with bio-oil or oxygen-containing or other heteroatom-containing hydrocarbon streams before being sent to the water treatment unit. Embodiment 37 is a process according to embodiment 21 or 27, wherein the separation unit comprises an atmospheric distillation unit and / or a vacuum distillation unit. Embodiment 38 is a process according to embodiment 21 or 27, wherein the separation unit is a flash evaporator. Embodiment 39 is a process according to embodiment 21 or 27, wherein the separation unit is a stripping unit that separates the light cut from the heavy cut with a stripping gas selected from the group consisting of hydrogen and saturated C1 to C4 gases. Embodiment 40 is a process according to embodiment 21 or 27, wherein the water treatment unit hydrocracking the hydrocarbon feed by contacting the hydrocarbon feed with a catalyst containing a particulate catalyst and / or a dissolved catalyst in a reactor with or without the presence of water, together with a recycle stream generated in an oil to chemical complex and added hydrogen. Embodiment 41 is a process according to embodiment 21 or 27, wherein the water treatment unit is selected from the group consisting of a fixed bed reactor, an ebullating bed reactor, a slurry reactor, and a jet circulation reactor. Embodiment 42 is a process according to embodiment 21 or 27, wherein the catalytic cracking unit is operated in a low severity mode, a high severity mode, or a hydrocracking mode.

[0052] *****

[0053] 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 can be made here 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 can easily understand from the above disclosure, currently existing or later developed processes, machines, manufactures, material compositions, means, methods or steps can be used, which perform functions substantially the same as the corresponding embodiments described herein or achieve substantially the same results. 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 low-sulfur diesel, the method comprising the following steps: flowing a hydrocarbon feed into a water treatment unit having a water treatment catalyst disposed therein; contacting the hydrocarbon feed with a first catalyst at a temperature of 275 to 400°C to produce a water treatment effluent having a boiling point of 35 to 650°C; separating the water treatment effluent to form a first stream comprising a hydrocarbon fraction having a boiling point below 305°C and a second stream comprising a hydrocarbon fraction having a boiling point above 305°C, wherein the second stream comprises diesel; and The second stream is hydrotreated to remove sulfur to produce a hydrotreated second stream comprising low sulfur diesel containing from 0 to 50 ppm sulfur.

2. The process of claim 1, wherein the second stream further comprises very low sulfur fuel oil containing 0 to 50 ppm sulfur.

3. The method according to claim 1, wherein the method further comprises the step of processing crude oil in a vacuum distillation unit to produce a vacuum distillation residue; wherein the hydrocarbon feed comprises the vacuum distillation residue; and / or wherein the method further comprises the step of separating the vacuum distillation product into a light vacuum distillation fraction, a heavy vacuum distillation fraction having a boiling point higher than the light vacuum distillation fraction, and a naphtha range fraction; and The heavy vacuum distillation fraction is fed from the bottom of the vacuum distillation unit to a water treatment unit.

4. The method of claim 1, further comprising the step of feeding the second stream to a steam cracking unit; and The second stream is steam cracked to produce olefins.

5. The method of claim 1, further comprising the step of flowing steam into a first water treatment unit, and / or wherein the first water treatment unit comprises a fixed bed reactor.

6. The method of claim 1, wherein the first catalyst comprises a particulate catalyst and a dissolved catalyst, preferably, wherein the dissolved catalyst comprises an organometallic compound having one or more of Ni, Mo, Co, W, Zr, preferably in the form of metal naphthenates and / or octoates, and / or wherein the dispersed portion of the catalyst is selected from: alkali metal hydroxides or oxides, Ni-Mo oxides, Ni-Mo sulfides, Co-Mo oxides or Co-Mo sulfides, W-Mo oxides, W-Mo sulfides, preferably on alumina or zeolites, or any combination of these.

7. A method for producing very low sulfur fuel oil, the method comprising the following steps: flowing a hydrocarbon feed into a water treatment unit having a water treatment catalyst disposed therein; contacting a hydrocarbon feed with a first catalyst at a temperature of 275 to 400° C. to produce a water treatment effluent; separating the water treatment effluent to form a first stream comprising a hydrocarbon fraction having a boiling point below 350°C and a second stream comprising a hydrocarbon fraction having a boiling point above 350°C, wherein the second stream comprises fuel oil; and The second stream is hydrotreated to remove sulfur, thereby producing a hydrotreated second stream comprising very low sulfur fuel oil having from 0 to 50 ppm sulfur.

8. The method of claim 7, further comprising the step of feeding the second stream to a steam cracking unit; and steam cracking the second stream to produce olefins; and / or Also included is the step of flowing steam into a first water treatment unit; and / or wherein the first water treatment unit comprises a fixed bed reactor.

9. The method of claim 7, wherein the first catalyst comprises a particulate catalyst and a dissolved catalyst, preferably, wherein the dissolved catalyst comprises an organometallic compound having one or more of Ni, Mo, Co, W, Zr, preferably in the form of metal naphthenates and / or octoates, and / or wherein the dispersed portion of the catalyst is selected from: alkali metal hydroxides or oxides, Ni-Mo oxides, Ni-Mo sulfides, Co-Mo oxides or Co-Mo sulfides, W-Mo oxides, W-Mo sulfides, preferably on alumina or zeolites, or any combination of these.

10. A method for steam cracking a feed produced by a water treatment process, the method comprising the steps of: flowing a hydrocarbon feed into a water treatment unit having a water treatment catalyst disposed therein; contacting the hydrocarbon feed with a first catalyst at a temperature of 275 to 400°C to produce a water treatment effluent having a boiling point of 35 to 400°C; and At least a first fraction of the water treatment effluent is fed to a steam cracker and the first fraction is steam cracked to produce olefins.

11. A method according to any one of the preceding claims, wherein the hydrocarbon feed further comprises pyrolysis oil; and / or wherein the pyrolysis oil is produced in a DPHG unit; and / or wherein the hydrocarbon feed comprises one or more of the following: crude oil, plastics, oligomers from pyrolysis of plastics, synthetic crude oil, crude oil fractions and hydrocarbons from pyrolysis of plastics.

12. A method for processing a hydrocarbon feed, the method comprising the steps of: flowing the hydrocarbon feed into a water treatment unit having a first catalyst disposed therein, wherein the hydrocarbon feed is a heavy feed from a vacuum distillation unit; contacting the hydrocarbon feed with a first catalyst at a temperature of 275 to 400°C to produce a water treatment effluent having a boiling point of 35 to 650°C; separating the water treatment effluent to form a first light stream comprising a hydrocarbon fraction having a boiling point of 25 to 300° C., a first heavy stream comprising a hydrocarbon fraction having a boiling point of more than 300° C., and a gaseous stream; separating the first light stream into a second light stream having a boiling point of 70 to 140° C. and a remaining light fraction; feeding the second light stream into a catalytic naphtha reformer comprising a second catalyst to produce aromatics by contacting the second light stream with the second catalyst; and feeding the remaining light fraction to a first steam cracker or a first catalytic naphtha cracker comprising a naphtha catalytic cracking catalyst; wherein the first heavy stream is recycled to the first water treatment unit, or wherein the first heavy stream is saturated by hydrogenation with hydrogen and fed to the first steam cracker or to a catalytic cracking unit comprising a fifth catalyst.

13. The process according to claim 12, wherein the gaseous stream is fed to a steam cracker; and / or wherein the gaseous stream is separated into a stream comprising ethane, a stream comprising butanes and a stream comprising propane.

14. A method for co-producing diesel, lubricant base oils and high-value chemicals in an integrated petroleum-to-chemicals plant, the method comprising the steps of: passing a hydrocarbon feed into a separation unit to produce a first light stream and a heavy fraction; feeding the heavy fraction into a water treatment unit having a water treatment catalyst disposed therein; contacting the heavy fraction with the water treatment catalyst at a temperature of 275 to 400° C. to produce a water treatment effluent having a boiling point range of 35 to 650° C.; Separating the water treatment effluent to form a first water treatment stream comprising a hydrocarbon fraction having a boiling point below 305°C, a second water treatment stream comprising a hydrocarbon fraction having a boiling point of 305 to 370°C, and a third water treatment stream having a boiling point greater than 370°C, wherein the second water treatment stream comprises diesel; and optionally hydrotreating the second stream to remove sulfur to produce a hydrotreated second stream comprising low sulfur diesel, the low sulfur diesel containing less than 50 ppm sulfur; feeding the third water-treated stream to a hydroisomerization and cracking unit to produce a lubricating oil base stock; feeding the light stream and the first water-treated stream to a steam cracker to produce olefins and residual pyrolysis oil; And the residual pyrolysis oil is recycled to the water treatment unit.

15. A process according to claim 14, wherein the light stream is fed to a gas unit and a VDU naphtha stream having a boiling point of up to 220°C is fed to a steam cracker.

16. The process of claim 15, wherein the light stream is fed to a gas plant which separates the light gases into a condensed naphtha stream and a gas plant gas stream which is fed to the steam cracker, wherein the gas plant gas stream is optionally separated into ethane and LPG, and the ethane is optionally fed to an ethane cracker, and the LPG is optionally fed to an LPG steam cracker.

17. The process according to claim 15, wherein the light stream is fed to a gas plant, the gas plant separates the light gas into a condensed naphtha stream and a gas stream, the condensed naphtha stream is further fed to a naphtha steam cracker, the gas stream is further separated into ethane, propane and butane, the ethane, propane and butane are fed to an ethane cracker, a propane cracker or a propane dehydrogenation unit, a butane cracker or a butane dehydrogenation unit.

18. The process according to claim 14, wherein the first stream is further separated to produce a gaseous effluent which is fed to a gas plant, and optionally a remaining liquid effluent which is fed to a naphtha steam cracker; and / or wherein the third stream is recovered as a fuel oil stream.

19. A method for co-producing diesel and high value chemicals in a petroleum to chemicals complex, the method comprising the steps of: passing a hydrocarbon feed into a separation unit to separate into a light fraction and a heavy fraction; feeding the heavy fraction into a water treatment unit having a water treatment catalyst disposed therein; contacting the heavy fraction with the water treatment catalyst at a temperature of 275 to 400° C. to produce a water treatment effluent having a boiling point range of 35 to 650° C.; separating the water treatment effluent to form a first stream comprising a hydrocarbon fraction having a boiling point below 305°C, a second stream comprising a hydrocarbon fraction having a boiling point greater than 305°C, wherein the second stream is fed to a catalytic cracking unit to produce high-value chemicals, saturated gas and residual liquid; The light fraction and the first stream are fed to a steam cracker to produce high-value chemicals and residual pyrolysis oil; the residual liquid and the residual pyrolysis oil are recycled back to the water treatment unit.

20. The process according to claim 19, wherein the light fraction comprises a light gas stream fed to a gas unit and saturated gas from a catalytic cracking unit and a residual naphtha stream with a boiling point up to 220°C fed to a steam cracker.

21. The process according to claim 19, wherein the light gas stream is fed to a gas unit, the gas unit separates the light gas stream into a condensed naphtha stream, the condensed naphtha stream is further sent to a steam cracker, the gas stream is further separated into ethane and LPG, and fed to ethane and LPG steam crackers respectively.

22. The process according to claim 20, wherein the light gas stream is fed to a gas plant, the gas plant separates the light gas stream into a condensed naphtha stream and a gas stream, the condensed naphtha stream is further fed to a naphtha steam cracker, the gas stream is further separated into ethane, propane and butane, the ethane, propane and butane are fed to an ethane cracker, a propane cracker or a propane dehydrogenation unit, a butane cracker or a butane dehydrogenation unit.

23. The process of claim 19, wherein the first stream is divided into a gaseous effluent and the gaseous effluent is fed to a gas plant, and optionally the remaining liquid effluent is fed to a naphtha steam cracker.

24. The process according to claims 14 and 19, wherein the first stream is split to produce a 70-140°C fraction and a light liquid stream.

25. The process as claimed in claim 24, wherein 70°C to -140°C is fed to a catalytic naphtha reformer to produce BTX aromatics and the saturated gas stream is sent to a common gas plant and a non-aromatic liquid stream.

26. The process of claim 24, wherein the remaining light liquid and non-aromatic liquid stream is fed to a naphtha steam cracker.

27. The process according to any one of the preceding claims, wherein the hydrocarbon feed is selected from crude oil, hydrogenated bio-oil, oligomers derived from plastic synthetic crude oil and pyrolysis oil derived from plastic, unconverted oil from refineries, pyrolysis oil and heavy residues from steam crackers.

28. The process of claim 14 or 19, wherein the heavy fraction is fed to the water treatment unit and optionally mixed with a bio-oil or a hydrocarbon stream containing oxygen or other heteroatoms before being sent to the water treatment unit.

29. The method according to claim 14 or 19, wherein the separation unit comprises an atmospheric distillation unit and / or a vacuum distillation unit.

30. The process of claim 14 or 19, wherein the separation unit is a flash evaporator.

31. The process according to claim 14 or 19, wherein the separation unit is a stripping unit, wherein the light fraction is separated from the heavy fraction using a stripping gas selected from hydrogen and saturated C1-C4 gases.

32. The process of claim 14 or 19, wherein the water treatment unit hydrocracking the hydrocarbon feed by contacting the hydrocarbon feed with a catalyst consisting of a particulate catalyst and / or a dissolved catalyst in a reactor with or without the presence of water and a recycle stream produced in an oil to chemicals complex and added hydrogen.

33. The process of claim 14 or 19, wherein the water treatment unit is selected from the group consisting of a fixed bed reactor, an ebullated bed reactor, a slurry reactor, and a jet loop reactor.

34. The process according to claim 14 or 19, wherein the catalytic cracking unit is operated in low severity mode, high severity mode or hydropyrolysis mode.

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