Method for catalytically cracking crude oil in coaxial and concentric downstream and upstream reactor stages

Abstract

A process for producing a product from a crude oil includes separating the crude oil into at least a lower boiling fraction and a higher boiling fraction, and delivering the fractions to a reactor system including an upstream section and a downstream section. The outer boundary of the downstream section is defined by a first wall in a plane perpendicular to the central axis, and the outer boundary of the upstream section is defined by a first wall and a second wall in a plane perpendicular to the central axis. In another arrangement, the outer boundary of the upstream section is defined by a first wall in a plane perpendicular to the central axis, and the outer boundary of the downstream section is defined by a first wall and a second wall in a plane perpendicular to the central axis. The process includes cracking the lower boiling fraction in an upstream stage in the presence of a catalyst, and cracking the higher boiling fraction in a downstream reactor in the presence of a catalyst. The process includes delivering a catalyst from an upstream reactor to a downstream reactor, from the downstream reactor to a regenerator, and from the regenerator to the upstream reactor.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims priority to U.S. Patent Application Serial No. 18 / 052,308, filed on November 3, 2022, entitled "Method for Producing Petrochemical Products from Crude Oil", the entire content of which is incorporated herein by reference. TECHNICAL FIELD

[0003] Embodiments of the present disclosure generally relate to chemical processing, and more particularly, to methods for producing petrochemical products from crude oil. BACKGROUND ART

[0004] Ethylene, propylene, butene, butadiene, and aromatic compounds (such as benzene, toluene, and xylene) are basic intermediates in most of the petrochemical industry. They are typically obtained by thermal cracking (or steam cracking) of petroleum gases and distillates (such as naphtha, kerosene, or even gas oil). These compounds are also produced by refinery fluid catalytic cracking (FCC) processes in which classical heavy feeds (such as gas oil or residues) are converted. Typical FCC feeds range from hydrocracked bottoms to heavy feed fractions (such as vacuum gas oil and atmospheric residue); however, these feeds are limited. Currently, the second most important source for propylene production is refinery propylene from FCC reactor units. With the growing demand, FCC reactor unit owners are increasingly looking at the petrochemical market to increase their revenues by taking advantage of the economic opportunities that arise in the market.

[0005] The growing global demand for light olefins remains a major challenge for many integrated refineries. In particular, the production of some valuable light olefins (such as ethylene, propylene, and butene) has attracted increasing attention because pure olefin streams are considered the basic materials for polymer synthesis. The production of light olefins depends on several process variables, such as feed type, operating conditions, and catalyst type. SUMMARY OF THE INVENTION

[0006] Embodiments of the present disclosure relate to an improved reactor system for processing crude oil to produce light olefins. According to embodiments disclosed herein, crude oil can be separated into at least two fractions, each of which can be cracked in the disclosed reactor system. Embodiments of the reactor system described herein can include a riser section and a downer section, as described in more detail herein, where the riser section is generally disposed around the downer section, or the downer section is generally disposed around the riser section. The riser section and the downer section can have a shared wall. This arrangement of the riser section and the downer section of the reactor system can reduce heat loss from the reactor system and can reduce the overall footprint of the reactor system as compared to conventional reactor systems.

[0007] According to one or more embodiments described herein, a method for producing petrochemical products from crude oil includes separating the crude oil into at least a lower boiling point fraction and a higher boiling point fraction and delivering the lower boiling point fraction and the higher boiling point fraction to a reactor system. The reactor system includes a first generally prismatic wall disposed around a central axis, the central axis being oriented in a generally vertical direction. The reactor system includes a second generally prismatic wall disposed around the central axis, the cross-section of the second generally prismatic wall surrounding the cross-section of the first generally prismatic wall in a plane perpendicular to the central axis. The outer boundary of the downer section is defined by the first generally prismatic wall in a plane perpendicular to the central axis, and the outer boundary of the riser section is defined by the first generally prismatic wall and the second generally prismatic wall in a plane perpendicular to the central axis. The method includes cracking the lower boiling point fraction in the riser section in the presence of a catalyst to produce a first cracked reaction product. The catalyst and the lower boiling point fraction move in cocurrent flow and pass through the riser section in a generally upward direction. The method includes cracking the higher boiling point fraction in the downer reactor in the presence of a catalyst to produce a second cracked reaction product. The catalyst and the higher boiling point fraction move in cocurrent flow in a generally downward direction through the downer section. The method includes delivering the catalyst from the riser reactor to the downer reactor, from the downer reactor to a regenerator, and from the regenerator to the riser reactor, wherein the amount of coke on the catalyst is reduced in the regenerator.

[0008] According to one or more embodiments described herein, a method for producing petrochemical products from crude oil may include separating the crude oil into at least a lower boiling fraction and a higher boiling fraction, and delivering the lower boiling fraction and the higher boiling fraction to a reactor system. The reactor system includes an upflow section and a downflow section. The reactor system includes a first generally prismatic wall disposed about a central axis, the central axis being oriented in a generally vertical direction. The reactor system includes a second generally prismatic wall disposed about the central axis, the cross-section of the second generally prismatic wall surrounding the cross-section of the first generally prismatic wall in a plane perpendicular to the central axis. The outer boundary of the upflow section is defined by the first generally prismatic wall in a plane perpendicular to the central axis. The outer boundary of the downflow section is defined by the first generally prismatic wall and the second generally prismatic wall in a plane perpendicular to the central axis. The method includes cracking the lower boiling fraction in the upflow section in the presence of a catalyst to produce a first cracked reaction product, wherein the catalyst and the lower boiling fraction flow cocurrently and pass through the upflow section in a generally upward direction. The method includes cracking the higher boiling fraction in a downflow reactor in the presence of a catalyst to produce a second cracked reaction product, wherein the catalyst and the higher boiling fraction flow cocurrently in a generally downward direction through the downflow section. The method includes delivering the catalyst from the upflow reactor to the downflow reactor, from the downflow reactor to a regenerator, and from the regenerator to the upflow reactor, wherein the amount of coke on the catalyst is reduced in the regenerator.

[0009] Additional features and advantages of the described embodiments will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the described embodiments, including the detailed description which follows, the claims, as well as the drawings.

[0010] Brief Description of the Drawings

[0011] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, where like structures are denoted with like reference numerals, and where:

[0012] Figure 1 is a schematic overview of a hydrocarbon feed conversion system according to one or more embodiments described in the present disclosure;

[0013] Figure 2 is a vertical cross-sectional view of a reactor system according to one or more embodiments described in the present disclosure;

[0014] Figure 3 is a horizontal cross-sectional view of a reactor system according to one or more embodiments described in the present disclosure; and

[0015] Figure 4It is a general schematic diagram of a hydrocarbon feed conversion system according to one or more embodiments described in the present disclosure.

[0016] For the description of the simplified schematic diagram and the accompanying drawings, many valves, temperature sensors, electronic controllers, etc. that are available and well-known to those of ordinary skill in the art of certain chemical processing operations are not included. In addition, the accompanying components typically included in a typical chemical processing operation (such as an air supply device, a catalyst hopper, and a flue gas treatment system) are not shown. The accompanying components in the hydrocracking unit (such as bleed streams, a spent catalyst discharge subsystem, and a catalyst replacement subsystem) are also not shown. It should be understood that these components are within the spirit and scope of the embodiments of the present disclosure. However, operating components such as those described in the present disclosure can be added to the embodiments described in the present disclosure.

[0017] It should also be noted that the arrows in the drawings refer to process streams. However, the arrows can equivalently refer to transfer lines, which can be used to transfer process streams between two or more system components. Additionally, the arrows connected to system components define the inlets or outlets in each given system component. The arrow direction generally corresponds to the main direction of movement of the material of the flow contained within the physical transfer line indicated by the arrow. Furthermore, arrows that do not connect two or more system components represent product streams leaving the shown system or system inlet streams entering the shown system. The product streams can be further processed in an accompanying chemical processing system or can be commercialized as final products. The system inlet streams can be streams transferred from an accompanying chemical processing system or can be unprocessed feed streams. Some arrows can represent recycle streams, i.e., effluent streams that are recycled back to system components within the system. However, it should be understood that in some embodiments, any represented recycle stream can be replaced by a system inlet stream of the same material, and a portion of the recycle stream can leave the system as a system product.

[0018] In addition, the arrows in the drawings can schematically show the processing steps of transporting a flow from one system component to another. For example, an arrow pointing from one system component to another can represent "delivering" the effluent of the system component to another system component, which can include the contents of the process stream "leaving" or being "removed" from one system component and the contents of the product stream being "introduced" into another system component.

[0019] It should be understood that, according to the embodiments presented in the relevant drawings, an arrow between two system components may represent an unprocessed stream between the two system components. In other embodiments, the stream indicated by the arrow may have substantially the same composition throughout the conveyance between the two system components. Additionally, it should be understood that in one or more embodiments, the arrow may represent that at least 75 wt%, at least 90 wt%, at least 95 wt%, at least 99 wt%, at least 99.9 wt% or even 100 wt% of the stream is conveyed between system components. Thus, in some embodiments, such as if there is a slip stream, less than all of the stream indicated by the arrow may be conveyed between system components.

[0020] It should be understood that when two or more lines intersect in the schematic flow chart of the relevant drawings, two or more process streams "mix" or "merge". Mixing or merging may also include mixing by directly introducing two streams into the same reactor (like reactor), separation device or other system component. For example, it should be understood that when two streams are shown as being directly merged before entering a separation unit or reactor, in some embodiments, these streams may equivalently be introduced into the separation unit or reactor and mixed in the reactor.

[0021] Reference will now be made in more detail to various embodiments, some of which are shown in the drawings. Whenever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Detailed Description

[0022] Embodiments of the present disclosure relate to methods for producing petrochemical products (such as light olefins) from crude oil. These methods include separating a crude oil stream into at least a lower boiling fraction and a higher boiling fraction, and delivering the lower boiling fraction and the higher boiling fraction to a reactor system. The reactor system has an upper section and a lower section. The upper section and the lower section of the reactor system may be arranged as described in detail herein, and thus, either the upper section is arranged around the lower section, or the lower section is arranged around the upper section. The upper section and the lower section have a shared wall. This arrangement may reduce heat loss from the reactor system compared to a conventional reactor system, and may reduce the total footprint of the reactor system. The method may include cracking the lower boiling fraction in the upper section and cracking the higher boiling fraction in the lower section to form a product stream containing light olefins.

[0023] As used in the present disclosure, "reactor" refers to a vessel in which one or more chemical reactions may optionally occur between one or more reactants in the presence of one or more catalysts. For example, a reactor may include a tank or tubular reactor configured to operate as a batch reactor, a continuous stirred tank reactor (CSTR), or a plug flow reactor. Example reactors include packed bed reactors (such as fixed bed reactors and fluidized bed reactors). One or more "reaction zones" may be provided in the reactor. As used in the present disclosure, "reaction zone" refers to the region in the reactor where a specific reaction occurs. For example, a packed bed reactor having multiple catalyst beds may have multiple reaction zones, where each reaction zone is defined by the region of each catalyst bed.

[0024] As described herein, a "riser" is a type of reactor in which the general movement of the feed through the reactor is upward. A riser generally also has an upward catalyst flow such that the feed and the catalyst flow cocurrently. A "downer" is a type of reactor in which the general movement of the feed through the reactor is downward. A downer generally also has a downward catalyst flow such that the feed and the catalyst flow cocurrently.

[0025] As used in the present disclosure, "separation unit" refers to any separation device or system of separation devices that at least partially separates one or more chemicals mixed in a process stream from each other. For example, a separation unit may selectively separate materials of different chemicals, phases, or sizes from each other to form one or more chemical fractions. Examples of separation units include, but are not limited to, distillation columns, flash drums, separation drums, separation tanks, centrifuges, cyclones, filtration devices, collectors, scrubbers, expansion devices, membranes, solvent extraction devices, etc. It should be understood that the separation methods described in the present disclosure may not completely separate all of one chemical component from all of another chemical component. It should be understood that the separation methods described in the present disclosure "at least partially" separate different chemical components from each other, and it should be understood, even if not explicitly stated, that the separation may include only partial separation. As used in the present disclosure, one or more chemical components may be "separated" from a process stream to form a new process stream. Generally, a process stream may enter a separation unit and be split or separated into two or more process streams of desired compositions. Additionally, in some separation methods, a "lower boiling fraction" (sometimes referred to as a "light fraction") and a "higher boiling fraction" (sometimes referred to as a "heavy fraction") may leave the separation unit, and on average, the content of the lower boiling fraction stream has a lower boiling point than that of the higher boiling fraction stream. Other streams may be intermediate between the lower boiling fraction and the higher boiling fraction, such as an "intermediate boiling fraction".

[0026] As used in this disclosure, the term "high severity conditions" generally refers to an FCC temperature of 500 °C or higher and a weight ratio of catalyst to hydrocarbon (catalyst to oil ratio) equal to or greater than 5:1, all of which are more severe than typical FCC reaction conditions.

[0027] It should be understood that "effluent" generally refers to the stream that leaves a system component (such as a separation unit, reactor, or reaction zone) after a particular reaction or separation and generally has a different composition (at least proportionally) from the stream entering the separation unit, reactor, or reaction zone.

[0028] As used in this disclosure, "catalyst" refers to any substance that increases the rate of a particular chemical reaction. The catalysts described in this disclosure can be used to facilitate various reactions, such as but not limited to cracking (including aromatics cracking). As used in this disclosure, "cracking" generally refers to a chemical reaction in which carbon-carbon bonds are broken. For example, a molecule having carbon-carbon bonds is broken into more than one molecule by breaking one or more carbon-carbon bonds, or a compound including an alkyl or cyclic moiety (such as an alkane, cycloalkane, naphthalene, aromatic, etc.) is converted into an olefinic compound and / or a compound that does not include a cyclic moiety or has fewer cyclic moieties than before cracking.

[0029] As used in this disclosure, the term "spent catalyst" refers to, for example, a catalyst that has been introduced and passed through a cracking reaction zone to crack hydrocarbon material (such as a higher boiling fraction or a lower boiling fraction) but has not been regenerated in a regenerator. A partially spent catalyst refers to a catalyst that has not been completely spent. Generally, a spent catalyst has significantly reduced activity due to, for example, coke deposited on the catalyst. The activity of a partially spent catalyst may be reduced, but not as much as that of a spent catalyst. A "spent catalyst" may have coke deposited on the catalyst and may include partially coked catalysts as well as fully coked catalysts. The amount of coke deposited on a "spent catalyst" may be greater than the amount of coke remaining on a regenerated catalyst after regeneration.

[0030] As used in this disclosure, the term "regenerated catalyst" refers to a catalyst that is introduced into a cracking reaction zone and then regenerated in a regenerator to heat the catalyst to a higher temperature, oxidize, and remove at least a portion of the coke from the catalyst to restore at least a portion of the catalytic activity of the catalyst, or both. Compared to a spent catalyst, a "regenerated catalyst" may have less coke, a higher temperature, or both, and may have greater catalytic activity compared to a spent catalyst. Compared to a fresh catalyst that has not passed through a cracking reaction zone and a regenerator, a "regenerated catalyst" may have more coke and lower catalytic activity.

[0031] It should be further understood that a stream can be named according to the components of the stream, and the components used to name the stream can be the main components of the stream (for example, including from 50 wt% (wt%), 70 wt%, 90 wt%, 95 wt%, 99 wt%, 99.5 wt% or even 99.9 wt% of the content of the stream to 100 wt% of the content of the stream). It should also be understood that when a stream containing components is disclosed as being delivered from one system component to another system component, the components of the stream are disclosed as being delivered from the one system component to the other system component. For example, the disclosure of delivering a "propylene stream" from a first system component to a second system component should be understood as equivalently disclosing delivering "propylene" from the first system component to the second system component, etc.

[0032] Figure 1 and Figure 4 each illustrate an embodiment of the hydrocarbon feed conversion system 100 described in detail in the present disclosure. In addition to the arrangement of the upflow section 120 and the downflow section 140 of the reactor system 150 included in each figure, Figure 1 and Figure 4 the hydrocarbon feed conversion systems 100 shown therein are largely similar. Now refer to Figure 1 to describe an embodiment of the hydrocarbon feed conversion system. However, it should be noted that most of the description of the hydrocarbon feed conversion system 100 referred to in Figure 1 also applies to the embodiment shown in Figure 4 .

[0033] Now refer to Figure 1 , the hydrocarbon feed conversion system 100 can include a feed separator 110, a reactor system 150 including an upflow section 120 and a downflow section 140, and a regenerator 130. The hydrocarbon feed conversion system 100 generally receives a crude oil stream 102 and directly processes the crude oil stream 102 to produce system product streams 122, 142.

[0034] Generally, the hydrocarbon feed conversion system 100 includes a reactor system 150 comprising an upflow section 120 and a downflow section 140, wherein a portion of the crude oil stream 102 contacts heated fluidized catalytic particles in a cracking reaction zone maintained at high severity temperature and pressure. As this portion of the crude oil stream 102 contacts the hot catalyst and is cracked into lighter products, a carbonaceous deposit commonly referred to as coke forms on the catalyst. The coke deposit formed on the catalyst can reduce the catalytic activity of the catalyst or deactivate the catalyst. The deactivation of the catalyst can cause the catalyst to become catalytically ineffective. The spent catalyst with the coke deposit can be separated from the cracking reaction products, the strippable hydrocarbons can be removed, and it can be delivered to a regeneration process, where the coke is burned from the catalyst in the presence of air to produce a catalytically effective regenerated catalyst. The term "catalytically effective" refers to the ability of the regenerated catalyst to increase the rate of the cracking reaction. The term "catalytic activity" refers to the extent to which the regenerated catalyst increases the rate of the cracking reaction and may be related to the number of catalytically active sites available on the catalyst. For example, the coke deposit on the catalyst can cover or block the catalytically active sites on the spent catalyst, thereby reducing the number of available catalytically active sites, which can reduce the catalytic activity of the catalyst. After regeneration, the regenerated catalyst can have a coke content equal to or less than 10 wt%, 5 wt%, or even 1 wt% based on the total weight of the regenerated catalyst. The combustion products can be removed from the regeneration process as a flue gas stream. Then, the heated regenerated catalyst can be recycled back to the cracking reaction zone of the reactor system 150.

[0035] The crude oil stream 102 can generally contain crude oil. As used in this disclosure, the term "crude oil" should be understood to refer to a mixture of petroleum liquids, gases, solids, or combinations thereof, including in some embodiments impurities such as sulfur-containing compounds, nitrogen-containing compounds, and metal compounds that have not undergone significant separation or reaction processes. Crude oil is different from fractions of crude oil. In certain embodiments, the crude oil feedstock can be light crude oil that has been minimally processed to provide a crude oil feedstock having a total metal (Ni + V) content of less than 10 parts per million by weight (ppmw) and a Conradson carbon residue of less than 5 wt%. For example, the minimal processing can include hydrotreating to remove, for example, heavy metals.

[0036] In one or more embodiments, the crude oil can have an American Petroleum Institute (API) gravity of 22 degrees to 40 degrees. For example, the hydrocarbon feed stream 102 used can be Arabian heavy crude oil (API gravity of about 28°), Arabian medium crude oil (API gravity of about 30°), Arabian light crude oil (API gravity of about 33°), or Arabian extra light crude oil (API gravity of about 39°).

[0037] Generally, based on the boiling point (a characteristic of the untreated crude oil that has not been separated into fractions), the contents of the crude oil stream 102 can include a relatively wide variety of chemical substances. For example, the crude oil stream 102 can have a composition such that the difference between the boiling point of 5 wt% and the boiling point of 95 wt% of the hydrocarbon feed stream 102 is at least 100 °C, at least 200 °C, at least 300 °C, at least 400 °C, at least 500 °C, or even at least 600 °C.

[0038] The crude oil stream 102 can be introduced into a feed separator 110, which can separate the contents of the crude oil stream 102 into at least a lower boiling point fraction stream 106 and a higher boiling point fraction stream 104. In one or more embodiments, at least 90 wt%, at least 95 wt%, at least 99 wt%, or even at least 99.9 wt% of the crude oil stream 102 can be present in the combination of the lower boiling point fraction stream 106 and the higher boiling point fraction stream 104. In one or more embodiments, the feed separator 110 can be a vapor-liquid separator, such as a flash tank (sometimes referred to as a breakpot, separation drum, separation tank, compressor suction drum, or compressor inlet drum). In embodiments where a vapor-liquid separator is used as the feed separator 110, the higher boiling point fraction stream 104 can leave the feed separator 110 as a liquid, and the lower boiling point fraction stream 106 can leave the feed separator 110 as a vapor. The vapor-liquid separator can be operated at a temperature and pressure suitable for separating the crude oil stream 102 into the lower boiling point fraction stream 106 and the higher boiling point fraction stream 104. The cut temperature or "cut point" of the vapor-liquid separator (i.e., the temperature of the approximate atmospheric boiling point at which the lower boiling point fraction stream 106 and the higher boiling point fraction stream 104 are separated) can be 250 °C to 400 °C. Thus, all components of the lower boiling point fraction stream can have a boiling point (at atmospheric pressure) of less than or equal to 400 °C, less than or equal to 375 °C, less than or equal to 350 °C, less than or equal to 325 °C, less than or equal to 300 °C, or less than or equal to 250 °C, and all components of the higher boiling point fraction stream can have a boiling point (at atmospheric pressure) of at least 250 °C, at least 300 °C, at least 325 °C, at least 350 °C, at least 375 °C, or at least 400 °C.

[0039] In one or more embodiments, the fractionation point may be about 350 °C, such as in the range of 340 °C to 360 °C or 345 °C to 355 °C. In these embodiments, if Arabian extra light crude oil is used as the feedstock, the 350 °C+ fraction may include 98.7 wt% slurry oil, 0.8 wt% light cycle oil, and 0.5 wt% naphtha. In these embodiments, the 350 °C- fraction may include 57.5 wt% naphtha, 38.9 wt% light cycle oil, and 3.7 wt% slurry oil.

[0040] Prior to introducing the crude oil stream 102 into the feed separator 110, one or more supplemental feed streams (not shown) may be added to the crude oil stream 102. As previously described, in one or more embodiments, the crude oil stream 102 may be crude oil. In one or more embodiments, the crude oil stream 102 may be crude oil, and one or more supplemental feed streams (comprising one or more of vacuum residue, tar sands, asphalt, atmospheric residue, vacuum gas oil, demetallized oil, naphtha streams, other hydrocarbon streams, or combinations of these materials) may be added to the crude oil upstream of the feed separator 110.

[0041] Still referring to Figure 1 , the lower boiling point fraction stream 106 and the higher boiling point fraction stream 104 may be delivered to the reactor system 150. The reactor system 150 may include an upflow section 120 and a downflow section 140. In one or more embodiments, the lower boiling point fraction stream 106 may be delivered to the upflow section 120 to be catalytically cracked, and the higher boiling point fraction stream 104 may be delivered to the downflow section 140 to be catalytically cracked. In the upflow section 120, the catalyst and the reactants flow cocurrently in a generally upward direction through the upflow section 120 during the reaction process. In the downflow section 140, the catalyst and the reactants flow cocurrently in a generally downward direction through the downflow section 140 during the reaction process. That is, the catalyst and the reactants have an upward superficial velocity in the upflow section 120, and the catalyst and the reactants have a downward superficial velocity in the downflow section 140. As described herein, "superficial velocity" refers to the velocity of a single phase flowing through a given cross-sectional area. The overall flow of the phase is used to determine the superficial velocity of the phase; thus, individual particles or molecules within the phase may move in a direction different from or even opposite to the overall flow of the phase without affecting the direction of the superficial velocity of the phase.

[0042] Figure 2 and Figure 3 A cross-sectional view of at least a portion of the reactor system 150 is shown in Figure 2 and Figure 3, the reactor system 150 may include a first generally prismatic wall 154 disposed about a central axis 152. In one or more embodiments, the central axis 152 may be oriented in a generally vertical direction. As used herein, a "generally vertical direction" means a direction within 10°, 5°, 2°, or even 1° of the vertical direction. The reactor system may further include a second generally prismatic wall 156 disposed about the central axis 152. The cross-section of the second generally prismatic wall 156 surrounds the cross-section of the first generally prismatic wall 154 in a plane perpendicular to the central axis 156.

[0043] As described herein, a "prismatic wall" refers to a wall that generally exhibits the profile of a three-dimensional prism. For example, but not limited to, a prismatic wall may exhibit the profile of a cylinder (circular prism) (as shown in Figure 2 and Figure 3 ), or a rectangular prism or any other polygonal prism not shown. A prismatic wall may have a cross-sectional shape in a plane perpendicular to the central axis. In one or more embodiments, the first generally prismatic wall 154 may have a circular, oval, elliptical, or polygonal cross-sectional shape in a plane perpendicular to the central axis 152. In one or more embodiments, the second generally prismatic wall 156 may have a circular, oval, elliptical, or polygonal cross-sectional shape in a plane perpendicular to the central axis 152.

[0044] As described herein, a wall may be generally prismatic. It should be understood that the walls of the reactor system 150 described herein may not be precisely prismatic. For example, but not limited to, the reactor walls may have openings for feed inlets, product outlets, and various sensors (such as, but not limited to, temperature sensors and pressure sensors). Additionally, the reactor walls may include minor defects in shape that do not affect the performance of the reactor but may prevent the reactor walls from presenting a precise prismatic shape. Thus, the walls of the reactor system 150 described herein may be "generally prismatic".

[0045] Referring now to the embodiment shown in Figure 3 , the first generally prismatic wall 154 may have a circular cross-sectional shape in a plane perpendicular to the central axis 152. The second generally prismatic wall 156 may have a circular cross-sectional shape in a plane perpendicular to the central axis 152. The first generally prismatic wall 154 may be at a first radial distance D 1 from the central axis 152, and the second generally prismatic wall may be at a second radial distance D 2 from the central axis 152. In one or more embodiments, the second radial distance D 2 may be greater than the first radial distance D 1 .

[0046] The upflow section 120 and the downflow section 140 of the reactor system may be defined by the generally prismatic walls of the reactor system 150. Figure 1 FIG. shows one embodiment of the reactor system 150, wherein the upflow section 120 is placed around the downflow section 140, and Figure 4 FIG. shows one embodiment of the reactor system 150, wherein the downflow section 140 is placed around the upflow section 120. Now referring to Figure 1 , the outer boundary of the downflow section 140 is defined by a first generally prismatic wall 154 in a plane perpendicular to the central axis 152. The outer boundary of the upflow section 120 is defined by the first generally prismatic wall 154 and a second generally prismatic wall 156 in a plane perpendicular to the central axis 152. In one or more embodiments, the cross-section of the downflow section 140 perpendicular to the central axis 152 is circular, and the cross-section of the upflow section 120 perpendicular to the central axis 152 is annular.

[0047] Now referring to Figure 4 , the outer boundary of the upflow section 120 is defined by a first generally prismatic wall 154 in a plane perpendicular to the central axis 152. The outer boundary of the downflow section 140 is defined by the first generally prismatic wall 154 and a second generally prismatic wall 156 in a plane perpendicular to the central axis 152. In one or more embodiments, the cross-section of the upflow section 120 perpendicular to the central axis 152 is circular, and the cross-section of the downflow section 140 perpendicular to the central axis 152 is annular.

[0048] Without being bound by theory, compared to a reactor system having a separate upflow reactor and a separate downflow reactor, as described herein, using a reactor system including an upflow section and a downflow section may reduce the total footprint of the reactor system. Conventional reactor systems, such as the reactor system described in U.S. Patent Application No. 17 / 570,526 (the entire content of which is incorporated herein by reference), utilize a separate upflow reactor and a separate downflow reactor. By arranging the upflow section and the downflow section as described herein, in a facility for processing crude oil to produce products such as light olefins, the reactor system may occupy less space than the separate upflow and downflow reactors of a conventional reactor system.

[0049] In addition, when compared again with a reactor system having a separate riser reactor and a separate downer reactor (such as the reactor system described in U.S. Patent Application No. 17 / 570,526), using a reactor system including a riser section and a downer section arranged as described in the present disclosure can shorten the standpipes required to transport the catalyst from the riser section to the downer section. For example, when using separate riser and downer reactors, standpipes are used to transport the catalyst between the riser and downer reactors, and between the regenerator and the reactor. In an embodiment of the reactor system of the present disclosure, the close proximity of the riser section and the downer section minimizes the need for standpipes between the riser section and the downer section of the reactor system. It should be noted that the minimization of standpipes in the reactor system and the relatively close arrangement of the riser section and the downer section in the reactor system described herein can also reduce the catalyst inventory of the reactor system. Accordingly, this can make it possible to use a smaller regenerator in the hydrocarbon feed conversion system described herein than is required in a conventional hydrocarbon feed conversion system. The minimization of the number of standpipes and the reduction in the size of the regenerator can reduce the cost of the process equipment required to construct and utilize the hydrocarbon feed conversion system described herein, providing an advantage over conventional systems.

[0050] In addition, relative to a reactor system using separate riser and downer reactors, using a reactor system including a riser section and a downer section arranged as described herein can reduce heat loss from the reactor system. Without being bound by theory, when using separate riser and downer reactors, heat may be lost from the riser reactor to the atmosphere and from the downer reactor to the atmosphere. On the other hand, when using the reactor system described herein, heat from only one of the riser section or the downer section can be transferred to the atmosphere. For example, depending on the configuration of the reactor system, the riser section or the downer section can serve as an additional insulator for the other section because the riser section and the downer section share a wall. This can reduce the heat lost to the atmosphere during the operation of the reactor system. Without being bound by theory, reducing the heat lost from the reactor system can reduce the need to burn fuel oil in the regenerator to maintain the heat balance of the reactor system. In a fluid catalytic cracking process with insufficient heat, heat can be added to the regenerator by burning fuel oil. The amount of fuel oil required can be significant, in some cases about 4 wt% to 5 wt% based on the total feed. Therefore, reducing heat loss from the reactor system can reduce fuel oil consumption and improve the overall economics of the reactor system operation.

[0051] Now referring to Figure 1 and Figure 4, in one or more embodiments, the upper section 120 may include a mixing zone 126 and a cracking reaction zone 127. The lower boiling point distillate stream 106 may be combined or mixed with the catalyst from the catalyst stream 132 in the mixing zone 126 and then cracked in the cracking reaction zone 127 to produce a mixture of semi-deactivated catalyst and a first cracking reaction product. The reactor system 150 may further include a first separator 128. The first separator 128 may be in fluid communication with the upper section 120 and the lower section 140. The first separator 128 may be operable to separate at least a portion of the first cracking reaction product from the semi-deactivated catalyst, such that the first cracking reaction product stream 122 may be delivered from the reactor system 150 and the semi-deactivated catalyst may be delivered to the lower section 140.

[0052] In one or more embodiments, the lower section 140 may include a mixing zone 146 and a cracking reaction zone 147. The higher boiling point distillate stream 104 may be combined with the semi-deactivated catalyst from the first separator 128 in the mixing zone 146 and then cracked in the cracking reaction zone 147 to produce a mixture of deactivated catalyst and a second cracking reaction product. The reactor system 150 may further include a second separator 148. The second separator 148 may be in fluid communication with the lower section 140 and the regenerator 130. The second separator 148 may be operable to separate at least a portion of the second cracking reaction product from the deactivated catalyst, such that the second cracking reaction product stream 142 may be delivered from the reactor system 150 and the deactivated catalyst may be delivered to the regenerator 130 as a deactivated catalyst stream 144.

[0053] According to one or more embodiments, the upper section 120 and the lower section unit 140 may be operated at a temperature of 500 °C to 700 °C. For example, the upper section 120 and the lower section 140 may be operated at a temperature of 500 °C to 525 °C, 525 °C to 550 °C, 550 °C to 575 °C, 575 °C to 600 °C, 600 °C to 625 °C, 625 °C to 650 °C, 650 °C to 675 °C, 675 °C to 700 °C, or any combination of these ranges.

[0054] According to some embodiments, the upstream section 120 may operate at a higher temperature than the downstream section 140. For example, the upstream section 120 may operate at a temperature of 600°C to 680°C, and the downstream section 140 may operate at a temperature of 580°C to 640°C. For example, the upstream section 120 may operate at a temperature of 600°C to 620°C, 620°C to 640°C, 640°C to 660°C, 660°C to 680°C, or any combination of these ranges. For example, the downstream section 140 may operate at a temperature of 580°C to 600°C, 600°C to 620°C, 620°C to 640°C, or a combination of these ranges. In an embodiment, the upstream section 120 may operate at a temperature that is at least 5°C higher, at least 10°C higher, at least 15°C higher, at least 20°C higher, at least 25°C higher, at least 30°C higher, at least 35°C higher, at least 40°C higher, at least 45°C higher, or even at least 50°C higher than the downstream section 140.

[0055] According to an embodiment, the ratio of catalyst to hydrocarbon in the upstream section 120 and the downstream section 140 may be from 10:1 to 30:1. For example, the ratio of catalyst to hydrocarbon in the upstream section 120 may be from 10:1 to 15:1, 15:1 to 20:1, 20:1 to 25:1, 25:1 to 30:1, or a combination of these ranges. The ratio of catalyst to hydrocarbon in the downstream section 140 may be from 10:1 to 15:1, 15:1 to 20:1, 20:1 to 25:1, 25:1 to 30:1, or a combination of these ranges.

[0056] In one or more embodiments, the residence time in the upstream section 120 (i.e., the average time of contact between the catalyst and the hydrocarbon) may be greater than the residence time in the downstream section 140, such as at least 0.1 second (sec), at least 0.2 second, at least 0.3 second, at least 0.4 second, at least 0.5 second, at least 0.6 second, at least 0.7 second, at least 0.8 second, at least 0.9 second, at least 1 second, at least 2 seconds, or even at least 3 seconds. Generally, when the sizes are somewhat similar, the upstream section may have a longer residence time than the downstream section. In an embodiment, the residence time of the upstream section 120 may be from 0.2 second to 5 seconds, 0.5 second to 1 second, 1 second to 1.5 seconds, 1.5 seconds to 2 seconds, 2 seconds to 2.5 seconds, 2.5 seconds to 3 seconds, or 3 seconds to 3.5 seconds, 3.5 seconds to 4 seconds, 4 seconds to 4.5 seconds, 4.5 seconds to 5 seconds, or a combination of these ranges. In an embodiment, the residence time of the downstream section 140 may be from 0.2 second to 5 seconds, 0.5 second to 1 second, 1 second to 1.5 seconds, 1.5 seconds to 2 seconds, 2 seconds to 2.5 seconds, 2.5 seconds to 3 seconds, or 3 seconds to 3.5 seconds, 3.5 seconds to 4 seconds, 4 seconds to 4.5 seconds, 4.5 seconds to 5 seconds, or a combination of these ranges.

[0057] The first cracking reaction product stream 122 and the second cracking reaction product stream 142 can each include a mixture of cracked hydrocarbon materials, which can be further separated into one or more higher value petrochemical products and recovered from the system. For example, the first cracking reaction product stream 122, the second cracking reaction product stream 142, or both can include one or more of cracked gas oil, cracked gasoline, cracked naphtha, mixed butenes, butadiene, propylene, ethylene, other olefins, ethane, methane, other petrochemical products, or combinations thereof. The cracked gasoline can be further processed to obtain aromatics, such as benzene, toluene, xylene, or other aromatics, for example.

[0058] Still referring Figure 1 and Figure 4 , the catalyst in the hydrocarbon feed conversion system 100 can be recycled by being delivered from the riser section 120 to the downcomer section 140, to the regenerator 130, and back to the riser section 120 in a continuous loop. Thus, the same catalyst is used in the reactions in the riser section 120 and the downcomer section 140.

[0059] In an embodiment, the regenerator 130 processes the catalyst by removing coke (i.e., at least most of the coke) and increasing the catalyst temperature (e.g., by combustion of the coke). As described herein, "removing" coke from the catalyst means removing at least a portion of the coke, but those skilled in the art will understand that some residual coke may remain on the catalyst. The catalyst delivered from the regenerator 130 to the riser section 120 is regenerated catalyst and has a relatively high catalytic activity. The catalyst delivered from the riser section 120 to the downcomer section 140 is semi-deactivated catalyst and has a medium catalytic activity. The catalyst delivered from the downcomer section 140 to the regenerator 130 is deactivated catalyst and has a relatively low catalytic activity.

[0060] The catalyst used in the hydrocarbon feed conversion system 100 may include one or more fluid catalytic cracking catalysts suitable for use in the riser section 120 and the downcomer section 140. The catalyst can be a heat carrier and can provide heat transfer to the riser section 120 and the downcomer section 140. The catalyst can also have multiple catalytically active sites, such as, for example, acidic sites that promote cracking reactions. For example, in an embodiment, the catalyst can be a high-activity FCC catalyst with high catalytic activity. Examples of fluid catalytic cracking catalysts suitable for use in the hydrocarbon feed conversion system 100 can include, but are not limited to, zeolites, silica-alumina catalysts, carbon monoxide combustion promoter additives, bottoms cracking additives, light olefin production additives, other catalyst additives, or combinations of these components. Zeolites that can be used as at least a portion of the catalyst for cracking can include, but are not limited to, Y, REY, USY, RE-USY zeolites, or combinations of these. The catalyst can also include shaped selective catalyst additives, such as ZSM-5 zeolite crystals or other pentasil-type catalyst structures commonly used in other FCC processes to produce light olefins and / or increase the octane of FCC gasoline. In one or more embodiments, the catalyst can include a mixture of ZSM-5 zeolite crystals, cracking catalyst zeolites, and the matrix structure of a typical FCC cracking catalyst. In one or more embodiments, the catalyst can be a mixture of Y and ZSM-5 zeolite catalysts embedded in clay, alumina, and a binder.

[0061] In one or more embodiments, at least a portion of the catalyst can be modified to include one or more rare earth elements (the 15 elements of the lanthanide series of the IUPAC periodic table plus scandium and yttrium), alkaline earth metals (Group 2 of the IUPAC periodic table), transition metals, phosphorus, fluorine, or any combination of these, which can increase the olefin yield in the riser section 120, the downcomer section 140, or both. Transition metals can include “an element whose atoms have a partially filled d subshell, or which can give rise to cations with an incomplete d subshell” [IUPAC, Compendium of Chemical Terminology, 2nd ed. (“Gold Book”) (1997). Online corrected version: (2006-) “transition element”]. One or more transition metals or metal oxides can also be impregnated onto the catalyst. The metal or metal oxide can include one or more metals from Groups 6-10 of the IUPAC periodic table. In some embodiments, the metal or metal oxide can include one or more of molybdenum, rhenium, tungsten, or any combination of these. In one or more embodiments, a portion of the catalyst can be impregnated with tungsten oxide.

[0062] The regenerator 130 can be any suitable combustion regenerator, where combustion gas such as air or other oxygen-containing gas streams is delivered into the regenerator 130 and flue gas is discharged. The combustion gas can include combustion air, oxygen, fuel gas, fuel oil, other components, or one or more of any combination thereof. In the regenerator 130, the coke deposited on the spent catalyst from the downcomer 140 can be at least partially oxidized (burned) in the presence of the combustion gas to form at least carbon dioxide and water. In some embodiments, the coke deposition on the spent catalyst can be fully oxidized in the regenerator 130. Other organic compounds, such as residual first cracking reaction products or, for example, second cracking reaction products, can also be oxidized in the regenerator 130 in the presence of the combustion gas. During the coke oxidation process in the regenerator 130, other gases, such as, for example, carbon monoxide, may be formed. The oxidation of the coke deposition generates heat, which can be transferred to and retained by the regenerated catalyst delivered to the riser 120 via the catalyst stream 132.

[0063] Generally, the regenerated catalyst has less coke deposition than the partially spent catalyst, and the partially spent catalyst has less coke deposition than the spent catalyst. The regenerated catalyst delivered from the regenerator 130 may have a coke deposition of less than 1 wt% based on the total weight of the regenerated catalyst. In some embodiments, the regenerated catalyst delivered from the regenerator 130 may have a coke deposition of less than 0.5 wt%, less than 0.1 wt% or less than 0.05 wt%. In some embodiments, the regenerated catalyst delivered from the regenerator 130 to the riser 120 may have a coke deposition of 0.001 wt% to 1 wt%, 0.001 wt% to 0.5 wt%, 0.001 wt% to 0.1 wt%, 0.001 wt% to 0.05 wt%, 0.005 wt% to 1 wt%, 0.005 wt% to 0.5 wt%, 0.005 wt% to 0.1 wt%, 0.005 wt% to 0.05 wt%, 0.01 wt% to 1 wt%, 0.01 wt% to 0.5 wt%, 0.01 wt% to 0.1 wt%, 0.01 wt% to 0.05 wt% based on the total weight of the regenerated catalyst. In one or more embodiments, the regenerated catalyst delivered from the regenerator 130 may be substantially free of coke deposition. As used in the present disclosure, the term "substantially free" of a component means that the component in a particular portion of the catalyst, stream or reaction zone is less than 1 wt%. As an example, a regenerated catalyst substantially free of coke deposition may have a coke deposition of less than 1 wt%. Removing the coke deposition from the regenerated catalyst in the regenerator 130 may remove the coke deposition from the catalytically active sites (such as, for example, acidic sites) of the catalyst that promote the cracking reaction. Removing the coke deposition from the catalytically active sites on the catalyst may increase the catalytic activity of the regenerated catalyst compared to the spent catalyst delivered from the downcomer 140. Thus, the regenerated catalyst may have a greater catalytic activity than the spent catalyst delivered from the downcomer 140 and the partially spent catalyst delivered from the riser 120 to the downcomer 140.

[0064] The regenerated catalyst may absorb at least a portion of the heat generated from the combustion of the coke deposition. The heat may cause the temperature of the regenerated catalyst to increase compared to the temperature of the spent catalyst.

[0065] The methods described herein have many advantages (over conventional FCC systems). For example, when the hydrocarbon feed stream 102 is split to form a higher boiling point distillate stream 104 and a lower boiling point distillate stream 106, the methods of the present disclosure allow for processing of the higher boiling point distillate stream 104 and the lower boiling point distillate stream 106 with different reaction conditions by utilizing a reactor system 150 including an upflow section 120 and a downflow section 140 and by circulating catalyst as described, thereby increasing conversion. Without being bound by theory, it is believed that the higher boiling point distillate stream 104 can be cracked with a lower temperature, a shorter residence time, and a less active catalyst compared to the lower boiling point distillate stream 106. The system described herein achieves this result by controlling the residence time by separately utilizing the upflow section 120 and the downflow section 140 in the reactor system 150. Moreover, by circulating catalyst as described, a large load of heat can be delivered to the upflow section 120 by combustion of the catalyst in the regenerator 130 immediately upstream. The lower temperature in the downflow section 140 is acceptable, allowing the catalyst to be delivered from the upflow section 120 to the downflow section 140 without an intermediate regeneration step. Additionally, the catalytic activity for processing the higher boiling point distillate stream 104 in the downflow section 140 may be relatively low, thus allowing for no need for a catalyst regeneration step immediately upstream of the downflow section 140.

[0066] Furthermore, it has been found that the cracking of the lower boiling point distillate stream 106 in the upflow section 120 does not form a large amount of coke, and thus the catalytic activity in the downflow section 140 is acceptable for cracking the heavier materials in the higher boiling point distillate stream 104. Without being bound by theory, it is believed that this reduced coking is due to the lower boiling point distillate stream 106 being less prone to cracking. However, the relatively easier cracking of the higher boiling point distillate stream 104 can lead to increased coking, which is immediately mitigated by directly delivering the catalyst from the downflow section 140 to the regenerator 130. Conventional systems can regenerate all of the catalyst entering the FCC and do not loop the catalyst through the upflow section 120, the downflow section 140, and the regenerator 130. Additionally, compared to conventional systems, the currently described system can use a reduced catalyst inventory because the catalyst is not regenerated between the upflow section 120 and the downflow section 140. As described herein, these and other advantages are presented by the presently disclosed embodiments.

[0067] Examples

[0068] Various embodiments of the methods and systems for the conversion of feedstock fuels will be further illustrated by the following examples. The examples are illustrative in nature and should not be construed as limiting the subject matter of the present disclosure.

[0069] Before testing, the catalyst was steam deactivated (100% steam for 6 hours at 810 °C). The deactivated catalyst was reacted with a lower boiling point distillate stream (Arabian super light crude oil at 350 °C - at a reactor temperature of 640 °C and a catalyst-to-oil ratio of 30 wt / wt). The catalyst leaving the reactor ("semi-deactivated catalyst") was collected in a stripping column. This semi-deactivated catalyst was kept under an inert (nitrogen) atmosphere and the deposited coke was not burned off. Multiple repeat runs were conducted to collect sufficient amounts of the catalyst for subsequent testing. The carbon remaining on the semi-deactivated catalyst was measured using a small sample (0.04 wt% carbon on the catalyst). The catalyst was then transferred back to the catalyst feed hopper under inert conditions and then used to react with a higher boiling point distillate stream of Arabian super light crude oil (350 °C +, labeled HF-AXL in Table 1). The test conditions for the corresponding yields are shown in the second column of Table 1, labeled semi-deactivated LF catalyst. These yields represent the HF-AXL yields when operating the system of the present disclosure, where the catalyst going to the reactor for processing the heavy fraction is first used to crack the lighter fraction. As a comparison, the third column of Table 1 shows the yields when cracking HF-AXL crude oil using a new (fresh) deactivated catalyst, where there is less coke. As shown, the yields of the products are comparable, indicating that the catalyst previously used to crack the light fraction was unexpectedly sufficient to crack the heavy fraction.

[0070] Table 1

[0071] Feed HF AXL HF AXL Catalyst Semi - deactivated LF Catalyst Deactivated Catalyst Carbon on Catalyst (wt%) 0.04 0.02 Reaction Temperature (°C) 608 610 Catalyst / Oil (wt / wt) 29 30 Yield, wt% Dry Gas & LPG 46.53 46.82 Liquid Product 53.47 53.18

[0072] According to a first aspect of the present disclosure, a method for producing petrochemical products from crude oil includes separating the crude oil into at least a lower boiling fraction and a higher boiling fraction, and delivering the lower boiling fraction and the higher boiling fraction to a reactor system. The reactor system includes an upper section and a lower section. The reactor system includes a first generally prismatic wall disposed around a central axis, the central axis being oriented in a generally vertical direction. The reactor system includes a second generally prismatic wall disposed around the central axis, the cross-section of the second generally prismatic wall surrounding the cross-section of the first generally prismatic wall in a plane perpendicular to the central axis. The outer boundary of the lower section is defined by the first generally prismatic wall in a plane perpendicular to the central axis, and the outer boundary of the upper section is defined by the first generally prismatic wall and the second generally prismatic wall in a plane perpendicular to the central axis. The method includes cracking the lower boiling fraction in the upper section in the presence of a catalyst to produce a first cracked reaction product. The catalyst and the lower boiling fraction flow cocurrently and pass through the upper section in a generally upward direction. The method includes cracking the higher boiling fraction in the downflow reactor in the presence of a catalyst to produce a second cracked reaction product. The catalyst and the higher boiling fraction flow cocurrently in a generally downward direction through the lower section. The method includes delivering the catalyst from the upflow reactor to the downflow reactor, from the downflow reactor to the regenerator, and from the regenerator to the upflow reactor, wherein the amount of coke on the catalyst is reduced in the regenerator.

[0073] A second aspect of the present disclosure may include the first aspect, wherein the first generally prismatic wall has a circular, oval, elliptical or polygonal cross-sectional shape in a plane perpendicular to the central axis, and the second generally prismatic wall has a circular, oval, elliptical or polygonal cross-sectional shape in a plane perpendicular to the central axis.

[0074] A third aspect of the present disclosure may include the first or second aspect, wherein the first generally prismatic wall has a circular cross-sectional shape in a plane perpendicular to the central axis, and the second generally prismatic wall has a circular cross-sectional shape in a plane perpendicular to the central axis, wherein the first generally prismatic wall is at a first radial distance from the central axis, the second prismatic wall is at a second radial distance from the central axis, and the second radial distance is greater than the first radial distance.

[0075] A fourth aspect of the present disclosure may include any one of the first to third aspects, wherein the cross-section of the lower section perpendicular to the central axis is circular, and the cross-section of the upper section perpendicular to the central axis is annular.

[0076] A fifth aspect of the present disclosure may include any one of the first to fourth aspects, wherein the reactor system further includes a first separator and a second separator, wherein the first separator is in fluid communication with the upper section and the lower section, and wherein the second separator is in fluid communication with the lower section and the regenerator.

[0077] The sixth aspect of the present disclosure may include any one of the first to fifth aspects, wherein the reaction temperature in the upflow section is 620°C to 680°C, and the reaction temperature in the downflow section is 580°C to 640°C.

[0078] The seventh aspect of the present disclosure may include any one of the first to sixth aspects, wherein the residence time in the upflow section is 0.2 seconds to 5 seconds, and the residence time in the downflow section is 0.2 seconds to 2 seconds.

[0079] The eighth aspect of the present disclosure may include any one of the first to seventh aspects, wherein the ratio of the catalyst to the hydrocarbon in the upflow section and the downflow section is 10:1 to 30:1.

[0080] The ninth aspect of the present disclosure may include any one of the first to eighth aspects, wherein the fractionation point of the lower boiling fraction and the higher boiling fraction is 250°C to 400°C.

[0081] The tenth aspect of the present disclosure may include any one of the first to ninth aspects, wherein the first cracking reaction product, the second cracking reaction product, or both contain at least one of ethylene, propylene, butene, or pentene.

[0082] According to the eleventh aspect of the present invention, a method for producing petrochemical products from crude oil may include separating the crude oil into at least a lower boiling fraction and a higher boiling fraction, and delivering the lower boiling fraction and the higher boiling fraction to a reactor system. The reactor system includes an upflow section and a downflow section. The reactor system includes a first generally prismatic wall disposed around a central axis, the central axis being oriented in a generally vertical direction. The reactor system includes a second generally prismatic wall disposed around the central axis, the cross-section of the second generally prismatic wall surrounding the cross-section of the first generally prismatic wall in a plane perpendicular to the central axis. The outer boundary of the upflow section is defined by the first generally prismatic wall in a plane perpendicular to the central axis. The outer boundary of the downflow section is defined by the first generally prismatic wall and the second generally prismatic wall in a plane perpendicular to the central axis. The method includes cracking the lower boiling fraction in the upflow section in the presence of a catalyst to produce a first cracking reaction product, wherein the catalyst and the lower boiling fraction flow cocurrently and pass through the upflow section in a generally upward direction. The method includes cracking the higher boiling fraction in the downflow reactor in the presence of a catalyst to produce a second cracking reaction product, wherein the catalyst and the higher boiling fraction flow cocurrently in a generally downward direction through the downflow section. The method includes delivering the catalyst from the upflow reactor to the downflow reactor, from the downflow reactor to the regenerator, and from the regenerator to the upflow reactor, wherein the amount of coke on the catalyst is reduced in the regenerator.

[0083] The twelfth aspect of the present disclosure may include the eleventh aspect, wherein the first substantially prismatic wall has a circular, oval, elliptical or polygonal cross-sectional shape in a plane perpendicular to the central axis, and the second substantially prismatic wall has a circular, oval, elliptical or polygonal cross-sectional shape in a plane perpendicular to the central axis.

[0084] The thirteenth aspect of the present disclosure may include the eleventh or twelfth aspect, wherein the first substantially prismatic wall has a circular cross-sectional shape in a plane perpendicular to the central axis, and the second substantially prismatic wall has a circular cross-sectional shape in a plane perpendicular to the central axis, wherein the first prismatic wall is at a first radial distance from the central axis, the second prismatic wall is at a second radial distance from the central axis, and the second radial distance is greater than the first radial distance.

[0085] The fourteenth aspect of the present disclosure may include any one of the eleventh to thirteenth aspects, wherein the cross-section of the upward section perpendicular to the central axis is circular, and the cross-section of the downward section perpendicular to the central axis is annular.

[0086] The fifteenth aspect of the present disclosure may include any one of the eleventh to fourteenth aspects, wherein the reactor system further includes a first separator and a second separator, wherein the first separator is in fluid communication with the upward section and the downward section, and wherein the second separator is in fluid communication with the downward section region and the regenerator.

[0087] The sixteenth aspect of the present disclosure may include any one of the eleventh to fifteenth aspects, wherein the reaction temperature in the upward section is 620 °C to 680 °C, and the reaction temperature in the downward section is 580 °C to 640 °C.

[0088] The seventeenth aspect of the present disclosure may include any one of the eleventh to sixteenth aspects, wherein the residence time in the upward section is 0.2 seconds to 5 seconds, and the residence time in the downward section is 0.2 seconds to 2 seconds.

[0089] The eighteenth aspect of the present disclosure may include any one of the eleventh to seventeenth aspects, wherein the ratio of catalyst to hydrocarbon in the upward section and the downward section is 10:1 to 30:1.

[0090] The nineteenth aspect of the present disclosure may include any one of the eleventh to eighteenth aspects, wherein the fractionation point of the lower boiling fraction and the higher boiling fraction is 250 °C to 400 °C.

[0091] The twentieth aspect of the present disclosure may include any one of the eleventh to nineteenth aspects, wherein the first cracking reaction product, the second cracking reaction product, or both contain at least one of ethylene, propylene, butene or pentene.

[0092] To define the present technology, a transitional phrase "consisting of" may be introduced in the claims as a closed preamble term to limit the scope of the claims to the recited components or steps and any naturally occurring impurities.

[0093] To define the present technology, a transitional phrase "consisting essentially of" may be introduced in the claims to limit the scope of one or more claims to the recited elements, components, materials or method steps, and any unrecited elements, components, materials or method steps that do not materially affect the novel features of the claimed subject matter.

[0094] The transitional phrases "consisting of" and "consisting essentially of" may be interpreted as subsets of open-ended transitional phrases (such as "comprising" and "including"), such that any statement using an open-ended phrase to introduce a series of elements, components, materials or steps should be interpreted as also disclosing a statement of a series of elements, components, materials or steps using the closed terms "consisting of" and "consisting essentially of". For example, a statement that a composition "comprises" components A, B and C should be interpreted as also disclosing that the composition "consists of" components A, B and C, and that the composition "consists essentially of" components A, B and C.

[0095] Any quantitative value expressed in this application may be considered to include open-ended embodiments consistent with the transitional phrases "comprising" or "including", as well as closed or partially closed embodiments consistent with the transitional phrases "consisting of" and "consisting essentially of".

[0096] It should be understood that any two quantitative values assigned to a property may constitute a range of that property, and all combinations of ranges formed by all the recited quantitative values of a given property are contemplated in this disclosure. It should be understood that in some embodiments, the composition range of a chemical component in a stream or reactor should be understood to include a mixture of isomers of that component. For example, specifying a composition range of butene may include a mixture of various isomers of butene. It should be understood that the examples provide composition ranges of various streams, and the total amount of isomers of a specific chemical composition may constitute a range.

[0097] The subject matter of this disclosure has been described in detail by reference to specific embodiments. It should be understood that any detailed description of a component or feature of an embodiment does not necessarily imply that the component or feature is essential to a particular embodiment or to any other embodiment. Furthermore, it will be apparent to those skilled in the art that various modifications and variations can be made to the described embodiments without departing from the spirit and scope of the claimed subject matter.

Claims

1. A method for producing petrochemical products from crude oil, the method comprising: separating the crude oil into at least a lower boiling point fraction and a higher boiling point fraction; delivering the lower boiling point fraction and the higher boiling point fraction to a reactor system, the reactor system comprising an upper section and a lower section, wherein: the reactor system comprises a first generally prismatic wall arranged around a central axis, the central axis being oriented in a substantially vertical direction; the reactor system comprises a second generally prismatic wall arranged around the central axis, the cross-section of the second generally prismatic wall surrounding the cross-section of the first generally prismatic wall in a plane perpendicular to the central axis; the outer boundary of the lower section is defined by the first generally prismatic wall in the plane perpendicular to the central axis; the outer boundary of the upper section is defined by the first generally prismatic wall and the second generally prismatic wall in the plane perpendicular to the central axis; cracking the lower boiling point fraction in the upper section in the presence of a catalyst to produce a first cracked reaction product, wherein the catalyst and the lower boiling point fraction move cocurrently and pass through the upper section in a generally upward direction; cracking the higher boiling point fraction in the downflow reactor in the presence of a catalyst to produce a second cracked reaction product, wherein the catalyst and the higher boiling point fraction move cocurrently in a generally downward direction through the lower section; and delivering the catalyst from the upflow reactor to the downflow reactor, from the downflow reactor to a regenerator, and from the regenerator to the upflow reactor, wherein the amount of coke on the catalyst is reduced in the regenerator.

2. The method according to claim 1, wherein The first generally prismatic wall has a circular cross-sectional shape in a plane perpendicular to the central axis, and the second generally prismatic wall has a circular cross-sectional shape in a plane perpendicular to the central axis, wherein the first generally prismatic wall is at a first radial distance from the central axis, the second prismatic wall is at a second radial distance from the central axis, and the second radial distance is greater than the first radial distance.

3. The method according to claim 1 or 2, wherein, The cross-section of the lower section perpendicular to the central axis is circular, and the cross-section of the upper section perpendicular to the central axis is annular.

4. The method according to any one of claims 1 to 3, wherein The reactor system further comprises a first separator and a second separator, wherein the first separator is in fluid communication with the upper section and the lower section, and wherein the second separator is in fluid communication with the lower section and the regenerator.

5. The method according to any one of claims 1 to 4, wherein The reaction temperature in the upper section is 620 °C to 680 °C, and the reaction temperature in the lower section is 580 °C to 640 °C.

6. The method according to any one of claims 1 to 5, wherein The residence time in the upper section is 0.2 seconds to 5 seconds, and the residence time in the lower section is 0.2 seconds to 2 seconds.

7. The method according to any one of claims 1 to 6, wherein The fractionation point of the lower boiling point fraction and the higher boiling point fraction is 250 °C to 400 °C.

8. The method according to any one of claims 1 to 7, wherein The first cracked reaction product, the second cracked reaction product, or both comprise at least one of ethylene, propylene, butene, or pentene.

9. A method for producing petrochemical products from crude oil, the method comprising: Separate the crude oil into at least a lower boiling fraction and a higher boiling fraction; Deliver the lower boiling fraction and the higher boiling fraction to a reactor system comprising an upflow section and a downflow section, wherein: The reactor system comprises a first generally prismatic wall disposed about a central axis oriented in a generally vertical direction; The reactor system comprises a second generally prismatic wall disposed about the central axis, the cross-section of the second generally prismatic wall surrounding the cross-section of the first generally prismatic wall in a plane perpendicular to the central axis; The outer boundary of the upflow section is defined by the first generally prismatic wall in the plane perpendicular to the central axis; The outer boundary of the downflow section is defined by the first generally prismatic wall and the second generally prismatic wall in a plane perpendicular to the central axis; Crack the lower boiling fraction in the upflow section in the presence of a catalyst to produce a first cracked reaction product, wherein the catalyst and the lower boiling fraction move cocurrently and pass through the upflow section in a generally upward direction; Crack the higher boiling fraction in the downflow reactor in the presence of a catalyst to produce a second cracked reaction product, wherein the catalyst and the higher boiling fraction move cocurrently in a generally downward direction through the downflow section; and Deliver the catalyst from the upflow reactor to the downflow reactor, from the downflow reactor to a regenerator, and from the regenerator to the upflow reactor, wherein the amount of coke on the catalyst is reduced in the regenerator.

10. The method according to claim 9, wherein The first generally prismatic wall has a circular cross-sectional shape in the plane perpendicular to the central axis, and the second generally prismatic wall has a circular cross-sectional shape in the plane perpendicular to the central axis, wherein the first prismatic wall is at a first radial distance from the central axis, the second prismatic wall is at a second radial distance from the central axis, and the second radial distance is greater than the first radial distance.

11. The method according to claim 9 or 10, wherein, The cross-section of the upflow section perpendicular to the central axis is circular, and the cross-section of the downflow section perpendicular to the central axis is annular.

12. The method according to any one of claims 9 to 11, wherein, The reactor system further comprises a first separator and a second separator, wherein the first separator is in fluid communication with the upflow section and the downflow section, and wherein the second separator is in fluid communication with the downflow section region and the regenerator.

13. The method according to any one of claims 9 to 12, wherein, The reaction temperature in the upflow section is 620 °C to 680 °C, and the reaction temperature in the downflow section is 580 °C to 640 °C.

14. The method according to any one of claims 9 to 13, wherein, The residence time in the upflow section is 0.2 seconds to 5 seconds, and the residence time in the downflow section is 0.2 seconds to 2 seconds, and in the upflow section and the downflow section, the ratio of catalyst to hydrocarbon is 10:1 to 30:

1.

15. The method according to any one of claims 9 to 14, wherein, The first cracked reaction product, the second cracked reaction product, or both contain at least one of ethylene, propylene, butene, or pentene.

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