EP-4739754-A1 - PROCESS FOR EFFICIENT RECOVERY OF PRODUCTS FROM FCC & STEAM CRACKER COMBINED EFFLUENT

Abstract

Embodiments herein relate to solutions to maximize the recovery of ethylene, propylene and aromatics rich naphtha from crude oil processing. The schemes involve treating the effluent from Fluid Catalytic Cracking (FCC) to remove metals like AsH 3 , PH 3 , Hg, as well as impurities such as NOx and oxygen, before mixing it with the steam cracker effluent. The combined effluent is then cooled in a cold box and sent to various fractionators for separating the ethylene, propylene, and aromatics rich naphtha.

Inventors

• MISHRA, RAKESH, KUMAR
• MITTAL, SUMIT
• VARSHNEY, VISHAL
• BELWOOD, Ian
• JAIN, ANKUR
• GHOSH, Srikanta, Kumar
• AGRAWAL, Amit, Kumar
• Banerjee, Abhik
• GUNDALE, Mangesh, M.

Assignees

• Lummus Technology LLC

Dates

Publication Date

20260513

Application Date

20240702

Claims (16)

1. 1. A process for producing olefins and aromatics from wide boiling hydrocarbon feedstock, the process comprising: separating the wide boiling hydrocarbon feedstock into a light fraction and a heavy fraction; catalytically cracking the heavy fraction to produce a catalytically cracked effluent; fractionating the catalytically cracked effluent to recover at least a wet gas fraction, a naphtha range fraction, and a heavy catalytically cracked fraction; compressing and separating the wet gas fraction to form a light compressed fraction and a heavy compressed fraction; removing impurities from the light compressed fraction to form a purified light compressed fraction; stripping the heavy compressed fraction to recover a stripped heavy fraction and a stripper gas fraction; combining the stripper gas fraction with the wet gas fraction prior to the compressing and separating the wet gas fraction; thermally cracking the light fraction to produce a thermally cracked effluent; quenching and separating the thermally cracked effluent to recover a fuel oil fraction and a light thermally cracked fraction; combining the light thermally cracked fraction with the purified light compressed fraction to form a combined catalytic and thermally cracked light fraction; drying the combined catalytic and thermally cracked light fraction to form a dried lights fraction; separating the dried lights fraction to recover a C4+ hydrocarbon fraction and a C3- hydrocarbon fraction; splitting the C4+ hydrocarbon fraction into a one or more C5- hydrocarbon fractions and a C6+ hydrocarbon fraction; mixing the C6+ hydrocarbon fraction with the stripped heavy fraction to form a combined C6+ hydrocarbon fraction; partially hydrogenating the combined C6+ hydrocarbon fraction to form a hydrogenated C6+ hydrocarbon fraction; separating the hydrogenated C6+ hydrocarbon fraction to recover an offgas fraction, an aromatics rich naphtha fraction, and a raffinate fraction; and separating the C3- hydrocarbon fraction to recover an hydrogen-containing offgas fraction, an ethylene fraction, a propylene fraction, and a light paraffin fraction.
2. 2. The process as claimed in claim 1, further comprising feeding the naphtha range fraction to the catalytically cracking the heavy fraction.
3. 3. The process as claimed in any one of the above claims, further comprising feeding the light paraffin fraction to the thermally cracking the light fraction.
4. 4. The process as claimed in any one of the above claims, further comprising hydrogenating a portion of the one or more C5- hydrocarbon fractions to produce a hydrogenated C5- hydrocarbon fraction and feeding the hydrogenated C5- hydrocarbon fraction to the catalytically cracking the heavy fraction.
5. 5. The process as claimed in any one of the above claims, further comprising hydrogenating a portion of the one or more C5- hydrocarbon fractions to produce a hydrogenated C5- hydrocarbon fraction and feeding the hydrogenated C5- hydrocarbon fraction to the thermally cracking the light fraction.
6. 6. The process as claimed in any one of the above claims, further comprising feeding the raffinate fraction to the catalytically cracking the heavy fraction.
7. 7. The process as claimed in any one of the above claims, further comprising feeding the offgas fraction to the compressing and separating the wet gas fraction.
8. 8. A system for producing olefins and aromatics from a wide boiling hydrocarbon feedstock, the system comprising: a separation system for separating the wide boiling hydrocarbon feedstock into a light fraction and a heavy fraction; a fluid catalytic cracking unit for catalytically cracking the heavy fraction to produce a catalytically cracked effluent; a fractionation system for fractionating the catalytically cracked effluent to recover at least a wet gas fraction, a naphtha range fraction, and a heavy catalytically cracked fraction; a wet gas compression system for compressing and separating the wet gas fraction to form a light compressed fraction and a heavy compressed fraction; an impurities removal system for removing impurities from the light compressed fraction to form a purified light compressed fraction; a stripper for stripping the heavy compressed fraction to recover a stripped heavy fraction and a stripper gas fraction; a flow line for combining the stripper gas fraction with the wet gas fraction upstream of the wet gas compression system; a steam cracker system for thermally cracking the light fraction to produce a thermally cracked effluent; a quench and separation system for quenching and separating the thermally cracked effluent to recover a fuel oil fraction and a light thermally cracked fraction; a mixer for combining the light thermally cracked fraction with the purified light compressed fraction to form a combined catalytic and thermally cracked light fraction; a compression and drying system for drying the combined catalytic and thermally cracked light fraction to form a dried lights fraction; a lights separation system for separating the dried lights fraction to recover a C4+ hydrocarbon fraction and a C3- hydrocarbon fraction; a splitter for splitting the C4+ hydrocarbon fraction into one or more C5- hydrocarbon fractions and a C6+ hydrocarbon fraction; a mixer for mixing the C6+ hydrocarbon fraction with the stripped heavy fraction to form a combined C6+ hydrocarbon fraction; a hydrogenation system for partially hydrogenating the combined C6+ hydrocarbon fraction to form a hydrogenated C6+ hydrocarbon fraction; a heavies separation system for separating the hydrogenated C6+ hydrocarbon fraction to recover an offgas fraction, an aromatics rich naphtha fraction, and a raffinate fraction; and a product recovery section for separating the C3- hydrocarbon fraction to recover a hydrogen-containing offgas fraction, an ethylene fraction, a propylene fraction, and a light paraffin fraction.
9. 9. The system as claimed in claim 8, further comprising a flow line for feeding the naphtha range fraction to the fluid catalytic cracking unit.
10. 10. The system as claimed in any one of claims 8-9, further comprising a flow line for feeding the light paraffin fraction to the steam cracker system.
11. 11. The system as claimed in any one of claims 8-10, further comprising a flow line for feeding a portion of the one or more C5- hydrocarbon fractions to the fluid catalytic cracking unit.
12. 12. The system as claimed in claim 11, further comprising a hydrogenation system for hydrogenating the portion of the one or more C5- hydrocarbon fractions to produce a hydrogenated C5- hydrocarbon fraction fed to the fluid catalytic cracking unit.
13. 13. The system as claimed in any one of claims 8-12, further comprising a flow line for feeding a portion of the one or more C5- hydrocarbon fractions to the steam cracker system.
14. 14. The system as claimed in claim 1 , further comprising a hydrogenation system for hydrogenating the portion of the one or more C5- hydrocarbon fractions to produce a hydrogenated C5- hydrocarbon fraction fed to the steam cracker system.
15. 15. The system as claimed in any one of claims 8-14, further comprising a flow line for feeding the raffinate fraction to the fluid catalytic cracking unit.
16. 16. The system as claimed in any one of claims 8-15, further comprising a flow line for feeding the offgas fraction to the compression and drying system.

Description

PROCESS FOR EFFICIENT RECOVERY OF PRODUCTS FROM FCC AND STEAM CRACKER COMBINED EFFLUENT FIELD OF THE DISCLOSURE [0001] Embodiments of the present disclosure generally relate to the recovery of petrochemical building blocks such as ethylene, propylene and aromatics rich naphtha from direct crude processing. BACKGROUND [0002] In recent years, the changing dynamics of the market have prompted refineries to explore new opportunities in petrochemical production from crude oil, shifting their focus beyond fuel production as fuel demand is depleting. Among the key building blocks for the petrochemical industry, ethylene and propylene hold significant importance. Due to the depleting demand of the fuels and increasing demand of the petrochemicals, refiners are being compelled to find the options to maximize petrochemicals from processing a variety of crude oils. Ethylene and propylene are expected to be in high demand, as they are the primary feed stock for the petrochemical/polymer industries. [0003] Various processes have been proposed that integrate catalytic cracking and steam pyrolysis, such as US7128827, among others. However, mixing of catalytic cracking and steam cracker effluents poses a risk in cold box operations, as NOX depositions may occur in cold box operations typically used for recovery of ethylene. SUMMARY OF THE CLAIMED EMBODIMENTS [0004] In one aspect, embodiments disclosed herein relate to a process for producing olefins and aromatics from wide boiling hydrocarbon feedstock. The process includes separating the wide boiling hydrocarbon feedstock into a light fraction and a heavy fraction. [0005] The heavy fraction is catalytically cracked to produce a catalytically cracked effluent, which is fractionating to recover at least a wet gas fraction, a naphtha range fraction, and a heavy catalytically cracked fraction. The process further includes compressing and separating the wet gas fraction to form a light compressed fraction and a heavy compressed fraction. Impurities are removed from the light compressed fraction to form a purified light compressed fraction. The heavy compressed fraction is stripped to recover a stripped heavy fraction and a stripper gas fraction. The stripper gas fraction is combined with the wet gas fraction prior to the compressing and separating step. [0006] The light fraction is thermally cracked to produce a thermally cracked effluent, which is quenched and separated to recover a fuel oil fraction and a light thermally cracked fraction. The light thermally cracked fraction is combined with the purified light compressed fraction to form a combined catalytic and thermally cracked light fraction, which is dried to form a dried lights fraction, which is then separated to recover a C4+ hydrocarbon fraction and a C3- hydrocarbon fraction. The C4+ fraction is split into one or more C5- fractions and a C6+ fraction. The C6+ fraction is mixed with the stripped heavy fraction to form a combined C6+ fraction, which is partially or fully hydrogenated to form a hydrogenated C6+ fraction. The hydrogenated C6+ fraction is separated to recover an offgas fraction, an aromatics rich naphtha fraction, and a raffinate fraction. The C3- fraction is separated to recover a hydrogen-containing offgas fraction, an ethylene fraction, a propylene fraction, and a light paraffin fraction. [0007] In another aspect, embodiments disclosed herein relate to a system for producing olefins and aromatics from a wide boiling hydrocarbon feedstock. The system includes a separation system for separating the wide boiling hydrocarbon feedstock into a light fraction and a heavy fraction, and a fluid catalytic cracking unit for catalytically cracking the heavy fraction to produce a catalytically cracked effluent. A fractionation system is provided for fractionating the catalytically cracked effluent to recover at least a wet gas fraction, a naphtha range fraction, and a heavy catalytically cracked fraction. A wet gas compression system compresses and separates the wet gas fraction to form a light compressed fraction and a heavy compressed fraction. An impurities removal system is provided for removing impurities from the light compressed fraction to form a purified light compressed fraction. The system also includes a stripper for stripping the heavy compressed fraction to recover a stripped heavy fraction and a stripper gas fraction. A flow line is provided for combining the stripper gas fraction with the wet gas fraction upstream of the wet gas compression system. The system also includes a steam cracker system for thermally cracking the light fraction to produce a thermally cracked effluent, as well as a quench and separation system for quenching and separating the thermally cracked effluent to recover a fuel oil fraction and a light thermally cracked fraction. A mixer is provided for combining the light thermally cracked fraction with the purified light compressed fraction to form a combined catalytic and