# US 10,119,083 B2 · Method for converting a high-boiling hydrocarbon feedstock into lighter boiling hydrocarbon products

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- Number: US 10,119,083 B2
- Document ID: US10119083B2
- Status: Granted
- Kind: B2
- Application number: 15/121,275
- Filed: 2014-12-23
- Published: 2016-12-15
- Granted: 2018-11-06
- Earliest claimed: 2014-02-25
- Assignees: Saudi Basic Industries Corporation; Sabic Global Technologies B.V.
- Applicants: Saudi Basic Industries Corporation; Sabic Global Technologies B.V.
- Inventors: Arno Johannes Maria Oprins; Andrew Mark Ward; Ravichander Narayanaswamy
- Web page: https://patentgrep.com/patent/US10119083B2

## CPC

- C10G 69/06: including at least one step of thermal cracking in the absence of hydrogen
- C10G 9/36: with heated gases or vapours
- C10G 11/18: according to the "fluidised-bed" technique
- C10G 29/205: {by reaction with hydrocarbons added to the hydrocarbon oil}
- C10G 65/10: including only cracking steps
- C10G 65/12: including cracking steps and other hydrotreatment steps
- C10G 69/02: plural serial stages only
- C10G 2300/107: Atmospheric residues having a boiling point of at least about 538 °C
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES

## Abstract

A process for converting high boiling hydrocarbon feedstock into lighter boiling hydrocarbon products in which the lighter boiling hydrocarbon products are suitable feedstock for petrochemical processes.

## Claims

### Claim 1

A process for converting a high-boiling hydrocarbon feedstock into lighter-boiling hydrocarbon products, said lighter-hydrocarbon products being suitable as feedstocks for petrochemical processes, said converting process comprising:
feeding a heavy hydrocarbon feedstock to a cascade of hydrocracking unit(s), wherein the cascade of hydrocracking units comprises at least two hydrocracking units, wherein on of the units is a last hydrocracking unit in said cascade of hydrocracking units;
cracking said feedstock in the hydrocracking units;
separating said cracked feedstock into at least a stream comprising a light-boiling hydrocarbon fraction and a bottom stream comprising a heavier hydrocarbon fraction than said light-boiling fraction;
feeding said bottom stream of such a hydrocracking unit as a feedstock for a subsequent hydrocracking unit in said cascade of hydrocracking units, wherein process conditions in each hydrocracking unit are different from each other, in which temperature conditions from first to subsequent hydrocracking units increases, wherein a reactor type design of the last hydrocracking unit is of a slurry phase type;
sending the light-boiling hydrocarbon fractions from each of said hydrocracking units to petrochemical processes, comprising at least a gas steam cracking unit, a propane dehydrogenation unit, and a butane dehydrogenation unit and one or more units chosen from a pentane dehydrogenation unit and a mixed propane-butane dehydrogenation unit;
separating said light boiling hydrocarbon fractions into a stream comprising C2, a stream comprising C3 and a stream comprising C4;
feeding said stream comprising C3 to the propane dehydrogenation unit;
feeding said stream comprising C4 to the butane dehydrogenation unit; and
feeding said stream comprising C2 to the gas steam cracker unit.

### Claim 2 (depends on 1)

The process according to claim 1, wherein the lighter boiling hydrocarbon fractions from all hydrocracking units in said cascade of hydrocracking units are hydrocarbons having a boiling point higher than methane and equal to or lower than that of cyclobutane.

### Claim 3 (depends on 1)

The process according to claim 1, further comprising separating said cracked feedstock into a stream comprising hydrogen; and feeding said stream comprising hydrogen to a hydrocracking unit in said cascade of hydrocracking units.

### Claim 4 (depends on 1)

The process according to claim 1, wherein said heavy hydrocarbon feedstock is chosen from crude oil atmospheric distillation unit (ADU) including naphtha, ADU bottom stream, and atmospheric gas oils, and products from refinery processes.

### Claim 5 (depends on 1)

The process according to claim 1, wherein said hydrocracking units preceded by a hydrotreating unit and bottom stream of said hydrotreating unit is used as a feedstock for said first hydrocracking unit, wherein temperature in said hydrotreating unit is higher than in said first hydrocracking unit.

### Claim 6 (depends on 5)

The process according to claim 5, wherein a temperature in the cascade of hydrocracking units increases and temperature in said second hydrocracking unit is higher than in said hydrotreating unit.

### Claim 7 (depends on 5)

The process according to claim 5, wherein the reactor type design of said hydrotreating unit is of the fixed bed type.

### Claim 8 (depends on 5)

The process according to claim 5, wherein the reactor type design of said first hydrocracking unit is of the ebulated bed reactor type.

### Claim 9 (depends on 1)

The process according to claim 1, wherein a bottom stream of a final hydrocracking unit is recycled to an inlet of said final hydrocracking unit.

### Claim 10

A process for converting a high-boiling hydrocarbon feedstock into lighter-boiling hydrocarbon products, said lighter-hydrocarbon products being suitable as feedstocks for petrochemical processes, said converting process comprising:
feeding a heavy hydrocarbon feedstock to a cascade of hydrocracking unit(s),
cracking said feedstock in the hydrocracking unit(s),
separating said cracked feedstock into a stream comprising hydrogen, a stream comprising a light-boiling hydrocarbon fraction and a bottom stream comprising a heavier hydrocarbon fraction,
feeding said bottom stream of such a hydrocracking unit as a feedstock for a subsequent hydrocracking unit in said cascade of hydrocracking units, wherein process conditions in each hydrocracking unit are different from each other, in which the hydrocracking conditions from the first to subsequent hydrocracking units increase from least severe to most severe, wherein a reactor type design of the last hydrocracking unit is of a slurry phase type, and
sending the light-boiling hydrocarbon fractions from each of said hydrocracking units to petrochemical processes, comprising at least a gas steam cracking unit, a propane dehydrogenation unit, and a butane dehydrogenation unit and one or more units chosen from a pentane dehydrogenation unit and a mixed propane-butane dehydrogenation unit, wherein a catalyst is present in the cascade of hydrocracking units and a particle size of the catalyst present in the cascade of hydrocracking units decreases from the first hydrocracking unit to the subsequent hydrocracking unit.