CN-121986152-A - Method and system for converting crude oil into chemicals

Abstract

The present invention relates to systems and methods for processing crude oil to produce more chemical feedstocks such as light olefins, lubricant oils, and fuels. One such system includes processing different streams from a crude distillation unit by at least two diesel hydrotreaters operating at two different pressures.

Inventors

• K. F. Lawson

Assignees

• SABIC环球技术有限责任公司

Dates

Publication Date

20260505

Application Date

20241008

Priority Date

20231012

Claims (20)

1. 1. A process for producing light olefins, lubricating oils and fuels from a crude oil feedstock, the process comprising: Fractionating the crude oil feedstock to produce a first naphtha minus product, a kerosene fraction, a light atmospheric gas oil fraction, a heavy atmospheric gas oil fraction, a light vacuum gas oil fraction, a medium vacuum gas oil fraction, a heavy vacuum gas oil fraction, and a vacuum residuum fraction; Hydrotreating a first portion of the light atmospheric gas oil fraction and the kerosene fraction at a pressure of less than about 40 bar gauge to produce a first diesel product and a second naphtha minus product; Hydrotreating a second portion of the light atmospheric gas oil fraction and the light vacuum gas oil fraction at a pressure greater than about 60 bar gauge to produce a second diesel product and a third naphtha minus product; Cracking the heavy atmospheric gas oil fraction and the medium vacuum gas oil fraction in the presence of a first hydrocracking catalyst to produce a fourth naphtha minus product, a third diesel product, a base oil product, and unconverted oil product; Cracking unconverted oil and the vacuum residuum fraction in the presence of a second hydrocracking catalyst to produce fifth naphtha products, fourth diesel products, middle distillate products, and heavy distillate products; Feeding the first naphtha minus product, the second naphtha minus product, the third naphtha minus product, the fourth naphtha minus product, and the fifth naphtha product to produce light olefins; Treating the first diesel product, the second diesel product, the third diesel product, and the fourth diesel product to produce a fuel, and The base oil product and the heavy distillate product from the gas oil hydrocracker are fed to a lube oil production zone to produce lube oil.
2. 2. The method of claim 1, further comprising: Hydrotreating the medium distillate product at a pressure greater than about 60 bar gauge to produce the second diesel product and the third naphtha minus product.
3. 3. The method of claim 1, further comprising: Cracking the heavy distillate product in the presence of the first hydrocracking catalyst to produce the fourth naphtha minus product, the third diesel product, the base oil product, and the unconverted oil product.
4. 4. The process of claim 1, wherein the first portion of the light atmospheric gas oil fraction and the kerosene fraction are hydrotreated at a pressure in the range of about 25 bar gauge to about 40 bar gauge.
5. 5. The process of claim 1, wherein the second portion of the light atmospheric gas oil fraction and the light vacuum gas oil fraction are hydrotreated at a pressure in the range of about 60 bar gauge to about 80 bar gauge.
6. 6. The method of claim 1, further comprising: A portion of the vacuum residuum fraction is fed to a solvent deasphalting unit prior to being fed to cracking in the presence of the second hydrocracking catalyst to produce a deasphalted oil.
7. 7. The method of claim 1, wherein the lube oil production zone comprises selective hydrotreating, methyl tertiary butyl ether process, and full hydrotreating.
8. 8. A system for producing light olefins, lube oils, and fuels from a crude oil feedstock, the system comprising: A crude distillation unit configured to fractionate a crude feed to produce a first naphtha minus product, a kerosene fraction, a light atmospheric gas oil fraction, a heavy atmospheric gas oil fraction, a light vacuum gas oil fraction, a medium vacuum gas oil fraction, a heavy vacuum gas oil fraction, and a vacuum residuum fraction; a first diesel hydrotreater in fluid communication with the crude distillation unit and configured to receive a first portion of the light atmospheric gas oil fraction and the kerosene fraction to produce a first diesel product and a second naphtha minus product; A second diesel hydrotreater having dewaxing capability in fluid communication with the crude distillation unit and configured to receive a second portion of the light atmospheric gas oil fraction and the light vacuum gas oil fraction to produce a second diesel product and a third naphtha minus product; a gas oil hydrocracker in fluid communication with the crude distillation unit and configured to crack the heavy atmospheric gas oil, the medium vacuum gas oil fraction, and the heavy vacuum gas oil fraction to produce a fourth naphtha minus product, a third diesel product, a base oil product, and an unconverted oil product; A resid hydrocracker in fluid communication with the crude distillation unit and the gas oil hydrocracker and configured to crack the unconverted oil product and the vacuum resid fraction to produce a fifth naphtha product, a fourth diesel product, a middle distillate product, and a heavy distillate product; A steam cracking zone in fluid communication with the crude distillation unit, the first diesel hydrotreater, the second diesel hydrotreater, the gas oil hydrocracker, and the resid hydrocracker and configured to crack the first naphtha minus product, the second naphtha minus product, the third naphtha minus product, the fourth naphtha minus product, and the fifth naphtha product to produce light olefins; a fuel processing zone in fluid communication with the first diesel hydrotreater, the second diesel hydrotreater, the gas oil hydrocracker, and the resid hydrocracker and configured to process the first diesel product, the second diesel product, the third diesel product, and the fourth diesel product to produce a fuel, and A lube oil production zone in fluid communication with the gas oil hydrocracker and the resid hydrocracker and configured to process the base oil product and the heavy distillate product to produce a lube oil.
9. 9. The system of claim 8, further comprising: A solvent deasphalting unit configured to receive a portion of said vacuum residuum fraction and produce deasphalted oil and bitumen that are fed to said gas oil hydrocracker.
10. 10. The system of claim 8, wherein the gas oil hydrocracker is a fixed bed cracker.
11. 11. The system of claim 8, wherein the lube oil production zone comprises a selective hydrogenation unit, an MTBE production unit, and a full hydrogenation unit.
12. 12. The system of claim 8, wherein the first diesel hydrotreater operates at a pressure of less than about 40 bar gauge.
13. 13. The system of claim 8, wherein the second diesel hydrotreater operates at a pressure greater than about 60 bar gauge.
14. 14. The system of claim 8, wherein the first diesel hydrotreater operates at a pressure in a range of about 25 bar gauge to about 40 bar gauge.
15. 15. The system of claim 8, wherein the second diesel hydrotreater operates at a pressure in a range of about 60 bar gauge to about 80 bar gauge.
16. 16. The system of claim 8, wherein the second diesel hydrotreater is further configured to receive a medium distillate product from the resid hydrocracker.
17. 17. The system of claim 8, wherein the gas oil hydrocracker is further configured to receive heavy distillate products from the resid hydrocracker.
18. 18. The system of claim 8, wherein the resid hydrocracker is further configured to receive cracked oil from a second steam cracking unit.
19. 19. The system of claim 18, wherein the pyrolysis oil is derived from a mixed plastic slurry.
20. 20. The system of claim 8, wherein the resid hydrocracker is further configured to produce bitumen and marine resid fuel oil.

Description

Method and system for converting crude oil into chemicals Cross Reference to Related Applications The present application claims the benefit and priority of U.S. provisional application No.63/589,769, filed on 10/12 of 2023, which is incorporated herein by reference in its entirety. Technical Field The present disclosure relates generally to systems and methods for processing crude oil to produce more chemical feedstocks (e.g., light olefins, lubricants, and fuels). Background Conventional refineries are provided with process units that focus on maximizing transportation fuel production. The yield of chemical feedstock depends on refinery complexity. Crude Oil To Chemical (COTC) technology includes refinery complex configured to transfer production from transportation fuels to a refinery complex that produces greater than 40% chemicals per unit weight of oil. To promote increased demand for chemical feedstocks and reduced demand for transportation fuels, the percentage of chemicals per unit weight of oil must be greatly increased. Disclosure of Invention To address these industry needs and other technical deficiencies, applicants have developed systems and methods for processing crude oil into chemical feedstocks. Provided herein are methods for producing light olefins, lubricating oils, and fuels from crude oil feedstocks. In certain examples, the method includes the step of fractionating the crude oil feed to produce a first naphtha minus product, a kerosene fraction, a light atmospheric gas oil fraction, a heavy atmospheric gas oil fraction, a light vacuum gas oil fraction, a medium vacuum gas oil fraction, a heavy vacuum gas oil fraction, and a vacuum residuum fraction. The method includes hydrotreating a first portion of the light atmospheric gas oil fraction and the kerosene fraction at a pressure of less than about 40 bar gauge to produce a first diesel product and a second naphtha minus product, and hydrotreating a second portion of the light atmospheric gas oil fraction and the light vacuum gas oil fraction at a pressure of greater than about 60 bar gauge to produce a first tail gas, a second diesel product, and a third naphtha minus product. In certain examples, the first portion of the light atmospheric gas oil fraction and the kerosene fraction are subjected to hydrotreating at a pressure in the range of about 25 bar gauge to about 40 bar gauge. In certain examples, the second portion of the light atmospheric gas oil fraction and the light vacuum gas oil fraction are subjected to hydrotreating at a pressure in the range of from about 60 bar gauge to about 80 bar gauge. The method further includes hydrocracking the heavy atmospheric gas oil, the medium vacuum gas oil fraction, and the heavy vacuum gas oil fraction in the presence of a hydrocracking catalyst to produce a second tail gas, a fourth naphtha minus product, a third diesel product, a base oil product, and unconverted oil product. The second tail gas may be subjected to cracking in the presence of steam. The process further includes catalytically hydrocracking the unconverted oil product (which contains unconverted oil having a low paraffin content) and the vacuum residuum fraction to produce a third tail gas, a fifth naphtha minus product, a fourth diesel product, a middle distillate product, and a heavy distillate product. The method further includes cracking the first naphtha minus product, the second naphtha minus product, the third naphtha minus product, the fourth naphtha minus product, and the fifth naphtha minus product in the presence of steam to produce light olefins, and treating the first diesel product, the second diesel product, and the third diesel product to produce fuel. The process further includes feeding the base oil product and the heavy distillate product to a lube oil production zone to produce lube oil. The lube oil production zone may include selective hydrotreating, MTBE processes, and full hydrotreating. In certain examples, the heavy distillate product and/or deasphalted oil and bitumen and/or low sulfur fuel oil are fed to a gas oil hydrocracker. In certain examples, the second tail gas may be subjected to cracking in the presence of steam. In certain examples, a base oil product containing unconverted oil having a large paraffin content is subjected to a lube oil production zone or to cracking in the presence of steam. In certain examples, the pyrolysis oil from the steam cracker and/or the heavy aromatics stream from the aromatics extraction unit is subjected to hydrocracking along with unconverted oil product. In certain examples, the medium distillate product is subjected to hydrotreating at a pressure greater than about 60 bar gauge along with the second portion of the light atmospheric gas oil fraction and the light vacuum gas oil fraction. In certain examples, the heavy distillate products and/or deasphalted oil and bitumen and/or low sulfur fuel oil are subjected to hydrocracking in a gas oil hydrocra