# US 10,870,807 B2 · Process and system for conversion of crude oil to petrochemicals and fuel products integrating steam cracking, fluid catalytic cracking, and conversion of naphtha into chemical rich reformate > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,870,807 B2 - Document ID: US10870807B2 - Status: Granted - Kind: B2 - Application number: 15/817,148 - Filed: 2017-11-17 - Published: 2018-06-07 - Granted: 2020-12-22 - Earliest claimed: 2016-11-21 - Assignees: Saudi Arabian Oil Company - Applicants: Saudi Arabian Oil Company - Inventors: Mohammed Saeed Al-Ghamdi; Bader BaHammam; Naif Al Osaimi; Sami Barnawi - Web page: https://patentgrep.com/patent/US10870807B2 ## CPC - C10G 69/08: including at least one step of reforming naphtha - C07C 29/04: by hydration of carbon-to-carbon double bonds - C07C 31/12: containing four carbon atoms - C10G 11/02: characterised by the catalyst used - B01D 3/143: {by two or more of a fractionation, separation or rectification step} - C10G 7/06: Vacuum distillation - C10G 2300/1048: Middle distillates - C10G 2300/107: Atmospheric residues having a boiling point of at least about 538 °C - C10G 2300/1077: Vacuum residues - C10G 2400/02: Gasoline - C10G 2400/30: Aromatics - 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 - C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS - B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28) ## Abstract Process scheme configurations are disclosed that enable conversion of crude oil feeds with several processing units in an integrated manner into petrochemicals. The designs utilize minimum capital expenditures to prepare suitable feedstocks for the steam cracker complex. The integrated process for converting crude oil to petrochemical products including olefins and aromatics, and fuel products, includes mixed feed steam cracking, fluid catalytic cracking and conversion of naphtha to chemical rich reformate. Feeds to the mixed feed steam cracker include light products from hydroprocessing zones within the battery limits, recycle streams from the C3 and C4 olefins recovery steps, and raffinate from a pyrolysis gasoline and FCC naphtha aromatics extraction zone within the battery limits. Chemical reformate from straight run naphtha streams is used as an additional feed to the aromatics extraction zone and or the mixed feed steam cracker. ## Claims ### Claim 1 An integrated process for producing petrochemicals and fuel products from a crude oil feed comprising: separating from the crude oil feed, in an atmospheric distillation unit (ADU), at least a first ADU fraction comprising straight run naphtha, a second ADU fraction comprising at least a portion of middle distillates from the crude oil feed, and a third ADU fraction comprising atmospheric residue; separating from the third ADU fraction, in a vacuum distillation unit (VDU), at least a first VDU fraction comprising vacuum gas oil; hydroprocessing in a distillate hydroprocessing (DHP) zone middle distillates from the second ADU fraction, and recovering at least a first DHP fraction and a second DHP fraction, wherein the first DHP fraction comprises naphtha and the second DHP fraction is used for diesel fuel production; processing, in a catalytic reforming zone, naphtha from the first ADU fraction, and recovering chemical rich reformate; processing in a fluid catalytic cracking zone the first VDU fraction to produce at least a first FCC fraction corresponding to light olefins that are recovered as petrochemicals, a second FCC fraction corresponding to FCC naphtha and a third FCC fraction corresponding to cycle oil; steam cracking, in a mixed feed steam cracking (MFSC) zone, naphtha from the first ADU fraction and raffinate derived from an aromatics extraction zone, and, in a gas oil steam cracking (GOSC) zone, hydrotreated gas oil, wherein steam cracking operates under conditions effective to recover at least a mixed product stream H2, methane, ethane, ethylene, mixed C3s and mixed C4s; pyrolysis gas; and pyrolysis oil; recovering, from the mixed product stream, H2, methane, non-olefinic C2-C4s, and petrochemicals ethylene, propylene and butylenes, hydroprocessing pyrolysis gas from steam cracking in a naphtha hydroprocessing zone, and recovering hydrotreated pyrolysis gas; and separating aromatics from hydrotreated pyrolysis gas and chemical rich reformate from the catalytic reforming zone in the aromatics extraction zone for recovery of petrochemical aromatic products, and aromatics extraction zone raffinate, wherein the raffinate derived from aromatics extraction is all or a portion of the aromatics extraction zone raffinate. ### Claim 2 (depends on 1) The process as in claim 1, wherein the chemical reforming zone includes a semi-regeneration, cyclic regeneration or continuous catalyst regeneration arrangement enabling contact of the naphtha feed with mono-functional or bi-functional reforming catalyst, to produce the chemical rich reformate. ### Claim 3 (depends on 1) The process in claim 1, wherein naphtha is hydrotreated prior to processing in the catalytic reforming zone. ### Claim 4 (depends on 1) The process in claim 1, wherein an n-paraffin rich stream is separated from the naphtha prior to reforming, and wherein at least a portion of the paraffin rich stream is passed to the MFSC. ### Claim 5 (depends on 1) The process as in claim 1, further comprising hydrotreating the second FCC fraction to produce hydrotreated FCC naphtha. ### Claim 6 (depends on 5) The process as in claim 5, further comprising processing the hydrotreated FCC naphtha in the aromatics extraction complex for recovery of additional aromatic products and additional aromatics extraction zone raffinate that is recycled to the MFSC zone. ### Claim 7 (depends on 5) The process as in claim 5, further comprising recovering C5s from the hydrotreated FCC naphtha and recycling the recovered C5s to the MFSC zone. ### Claim 8 (depends on 7) The process as in claim 7, further comprising processing the hydrotreated FCC naphtha in the aromatics extraction complex for recovery of additional aromatic products and additional aromatics extraction zone raffinate that is recycled to the MFSC zone. ### Claim 9 (depends on 1) The process as in claim 1, wherein at least a significant portion of the first DHP fraction is passed to the MFSC zone or to the ADU. ### Claim 10 (depends on 1) The process as in claim 1, further comprising hydroprocessing in a gas oil hydroprocessing (GOHP) zone vacuum gas oil from the first VDU fraction prior to processing in the fluid catalytic cracking zone, and recovering a first GOHP fraction containing components boiling at or below an atmospheric residue end boiling point and including LPG, naphtha and middle distillate range components, and a second GOHP fraction containing heavy oil, which passed to the fluid catalytic cracking zone. ### Claim 11 (depends on 10) The process as in claim 10, wherein at least a significant portion of naphtha from the first GOHP fraction is routed to the MFSC zone or to the atmospheric distillation zone. ### Claim 12 (depends on 10) The process as in claim 10, wherein at least a significant portion of the first GOHP fraction is routed to the distillate hydroprocessing zone. ### Claim 13 (depends on 10) The process as in claim 10, further wherein the middle distillates in the second ADU fraction comprise heavy atmospheric gas oil that is processed in the gas oil hydroprocessing zone. ### Claim 14 (depends on 10) The process as in claim 10, further wherein the middle distillates in the second ADU fraction comprise heavy atmospheric gas oil that is processed in the fluid catalytic cracking zone without hydroprocessing, and the first VDU fraction is hydroprocessed in the gas oil hydroprocessing zone. ### Claim 15 (depends on 10) The process as in claim 10, further comprising passing at least a portion of the third FCC fraction in the distillate hydroprocessing zone. ### Claim 16 (depends on 10) The process as in claim 10, wherein the GOHP zone operates under hydrocracking conditions and in the presence of hydrocracking catalyst to convert 27-99 wt % of feed to the GOHP zone into the first GOHP fraction, and wherein the second GOHP fraction comprises unconverted oil. ### Claim 17 (depends on 10) The process as in claim 10, wherein the GOHP zone operates under hydrotreating conditions and in the presence of hydrotreating catalyst to convert 2-30 wt % of feed to the GOHP zone into the first GOHP fraction, and wherein the second GOHP fraction comprises hydrotreated gas oil. ### Claim 18 (depends on 10) The process as in claim 10, further wherein the middle distillates in the second ADU fraction comprise heavy atmospheric gas oil that is routed to the GOHP zone. ### Claim 19 (depends on 10) The process as in claim 10, further wherein the middle distillates in the second ADU fraction comprise heavy atmospheric gas oil that is processed in the GOSC zone without hydroprocessing. ### Claim 20 (depends on 10) The process as in claim 10, wherein the middle distillates in the second ADU fraction comprise kerosene that is processed in a kerosene sweetening process to recover a kerosene fuel product, and a straight run diesel fraction that is the portion of the second ADU fraction that is processed in the distillate hydroprocessing zone. ### Claim 21 (depends on 20) The process as in claim 20, further wherein the middle distillates in the second ADU fraction comprise heavy atmospheric gas oil that is processed in the GOHP zone or the GOSC zone. ### Claim 22 (depends on 1) The process as in claim 1, wherein at least a significant portion of the first DHP fraction is passed to the MFSC zone or to the ADU. ### Claim 23 (depends on 10) The process claim 10, wherein at least a significant portion of naphtha from the first GOHP fraction is routed to the catalytic reforming zone. ### Claim 24 (depends on 10) The process as in claim 10, wherein at least a significant portion of the first GOHP fraction is routed to the distillate hydroprocessing zone. ### Claim 25 (depends on 1) The process as in claim 1, further comprising separating non-olefinic C4s recovered from the mixed product stream, wherein said non-olefinic C4s are recycled to the MFSC zone. ### Claim 26 (depends on 1) The process as in claim 1, further comprising separating non-olefinic C4s recovered from the mixed product stream, wherein said non-olefinic C4s are recycled to a separate processing zone for production of additional petrochemicals. ### Claim 27 (depends on 26) The process as in claim 26, wherein the separate processing zone converts mixture of butenes into mixed butanols. ### Claim 28 (depends on 26) The process as claim 26, further comprising recovering C5s from the hydrotreated pyrolysis gas; passing the recovered C5s to the separate processing zone for production of additional petrochemicals; and passing a portion of the recovered ethylene to the separate processing zone; wherein the separate processing zone is a metathesis reaction zone which produces petrochemical propylene and a C4/C5 raffinate stream that is recycled to the MFSC zone. ### Claim 29 (depends on 1) The process as in claim 1, further comprising recovering C5s from the hydrotreated pyrolysis gas and passing the recovered C5s to the MFSC zone, a separate processing zone for production of additional petrochemicals, or both to the MFSC zone and a separate processing zone for production of additional petrochemicals. ### Claim 30 (depends on 29) The process as in claim 29 wherein the recovered C5s are passed to the MFSC zone. ### Claim 31 (depends on 29) The process as in claim 29 wherein the recovered C5s are passed to the separate processing zone for production of additional petrochemicals, wherein the separate processing zone converts mixture of butenes into mixed butanols. ### Claim 32 (depends on 1) The process as in claim 1, wherein a crude to chemicals conversion ratio of at least about 39 wt % is achieved.