Integrated hydrotreating and steam pyrolysis system including hydrogen redistribution for direct processing of a crude oil

An integrated hydrotreating and steam pyrolysis system for the direct processing of a crude oil to produce olefinic and aromatic petrochemicals, the system comprising:

• a separation zone having a heavy fraction outlet and a light fraction outlet;
• a catalytic hydroprocessing zone in fluid communication with the heavy fraction outlet of the separation zone having inlet for receiving a mixture of the heavy components and hydrogen recycled from a steam pyrolysis product stream effluent, and make-up hydrogen as necessary, and an outlet for discharging a hydroprocessed effluent, the catalytic hydroprocessing zone including a reactor operating under conditions effective to produce a hydroprocessed effluent;
• a hydroprocessed effluent vapor-liquid separator having an inlet in fluid communication with the hydroprocessing zone outlet, a vapor fraction outlet and a liquid fraction outlet,
• wherein the hydroprocessed effluent vapor-liquid separator includes
• a pre-rotational element having an entry portion and a transition portion, the entry portion having an inlet for receiving a flowing fluid mixture and a curvilinear conduit,
• a controlled cyclonic section having
• an inlet adjoined to the pre-rotational element through convergence of the curvilinear conduit and the cyclonic section,
• a riser section at an upper end of the cyclonic member through a vapor fraction outlet through which vapors pass;
• and
• a liquid collector/settling section through which liquid passes;
• the thermal cracking zone including
• a thermal cracking convection section with an inlet in fluid communication with the vapor fraction outlet of the hydroprocessed effluent vapor-liquid separator, and an outlet, and
• a thermal cracking pyrolysis section having an inlet in fluid communication with the outlet of the convection section and the light fraction outlet, and a pyrolysis section outlet;
• a quenching zone in fluid communication with the pyrolysis section outlet, the quenching zone having an outlet for discharging an intermediate quenched mixed product stream and an outlet for discharging quenching solution;
• a product separation zone in fluid communication with the intermediate quenched mixed product stream outlet, and having a hydrogen outlet, one or more olefin product outlets and one or more pyrolysis fuel oil outlets;
• and
• a hydrogen purification zone in fluid communication with the product separation zone hydrogen outlet, the hydrogen purification zone having an outlet in fluid communication with the hydroprocessing zone.

An integrated hydrotreating and steam pyrolysis system for the direct processing of a crude oil to produce olefinic and aromatic petrochemicals, the system comprising:

• a separation zone having a heavy fraction outlet and a light fraction outlet;
• a catalytic hydroprocessing zone in fluid communication with the heavy fraction outlet of the separation zone having inlet for receiving a mixture of the heavy fraction and hydrogen recycled from a steam pyrolysis product stream effluent, and make-up hydrogen as necessary, and an outlet for discharging a hydroprocessed effluent, the catalytic hydroprocessing zone including a reactor operating under conditions effective to produce a hydroprocessed effluent;
• a high pressure separator in fluid communication with the hydroprocessing zone reactor and having a gas portion outlet in fluid communication with the hydroprocessing zone reactor and a liquid portion outlet;
• a low pressure separator in fluid communication liquid portion outlet of the high pressure separator, and having a gas portion outlet and a liquid portion outlet;
• the thermal cracking zone including
• a thermal cracking convection section with an inlet in fluid communication with the liquid portion outlet of the low pressure separator, and an outlet, and
• a thermal cracking pyrolysis section having an inlet in fluid communication with the outlet of the convection section and the light fraction outlet, and a pyrolysis section outlet;
• a quenching zone in fluid communication with the pyrolysis section outlet, the quenching zone having an outlet for discharging an intermediate quenched mixed product stream and an outlet for discharging quenching solution;
• a product separation zone in fluid communication with the intermediate quenched mixed product stream outlet, and having a hydrogen outlet, one or more olefin product outlets and one or more pyrolysis fuel oil outlets;
• and
• a hydrogen purification zone in fluid communication with the product separation zone hydrogen outlet, the hydrogen purification zone having an outlet in fluid communication with the hydroprocessing zone.