US 2025/0051656 A1 · SYSTEMS AND METHODS TO UPGRADE A HYDROCARBON STREAM TO A LOWER BOILING POINT FEED MATERIAL

Abstract

Systems and methods for upgrading a hydrocarbon stream to a lower boiling point hydrocarbon feed material are disclosed. The system includes a feeding device to transport a hydrocarbon stream that includes an alternative feedstock. The hydrocarbon stream is partially cracked in a first cracking unit producing a lower boiling point hydrocarbon feed material, a catalyst rich heavy hydrocarbon stream, and coke. A slurry settler receives the catalyst rich heavy hydrocarbon stream and coke and separates the catalyst from the catalyst rich heavy hydrocarbon stream thereby defining a catalyst rich stream and a heavy hydrocarbon stream. A coking vessel receives the heavy hydrocarbon stream and coke and separates the heavy hydrocarbons from the coke thereby defining a heavy hydrocarbon stream. Finally, a second cracking unit that receives the lower boiling point feed material from the first cracking unit and produces olefins and aromatics.

Claims16

Dependent claims

A method for upgrading a hydrocarbon stream to a lower boiling point hydrocarbon feed material to produce olefins and aromatics at a high conversion rate and while preventing a pressure drop due to coke formation, the method comprising:

introducing a hydrocarbon stream that includes an alternative feedstock to a pre-heater, the pre-heater configured to heat the hydrocarbon stream and thereby define a pre-heated hydrocarbon stream;
supplying the pre-heated hydrocarbon stream to a first reactor;
operating the first reactor at a first pressure and a temperature to produce a lower boiling point hydrocarbon feed material, a heavy hydrocarbon stream, and coke from the pre-heated hydrocarbon stream;
transporting the heavy hydrocarbon stream and coke to a coke vessel;
separating the coke, in the coke vessel, from the heavy hydrocarbon stream to prevent substantial coke formation during operation of a second reactor;
transporting the lower boiling point hydrocarbon feed material from the first reactor and the heavy hydrocarbon stream to the second reactor;
and
operating the second reactor to produce olefins and aromatics from the lower boiling point hydrocarbon feed material and heavy hydrocarbon stream.

5 more elements

A system for upgrading crude oil to a lower boiling point hydrocarbon feed material, the system comprising:

a feeding device to transport a hydrocarbon stream that includes an alternative feedstock;
a first cracking unit that receives the hydrocarbon stream from the feeding device, the first cracking unit operable, at a first pressure, to partially crack the hydrocarbon stream via one or more of thermal cracking or catalytic cracking to produce a lower boiling point hydrocarbon feed material, a catalyst rich heavy hydrocarbon stream, and coke;
a slurry settler that receives the catalyst rich heavy hydrocarbon stream and coke from the first cracking unit, the slurry settler operable to separate the catalyst from the catalyst rich heavy hydrocarbon stream and coke thereby defining a catalyst rich stream, a heavy hydrocarbon stream, and coke, the catalyst rich stream being transported from the slurry settler for re-use or regeneration;
a coke settler that receives the heavy hydrocarbon stream and coke from the slurry settler, the coke settler operable to separate hydrocarbons from coke in the heavy hydrocarbon stream, thereby defining particulate coke and another hydrocarbon stream;
and
a second cracking unit that receives the lower boiling point feed material from the first cracking unit, the second cracking unit operable to produce olefins and aromatics.

3 more elements

Dependencies are inferred from the claim text.

Systems and methods to upgrade a hydrocarbon stream to a lower boiling point feed material

Life of this patent

Systems and methods to upgrade a hydrocarbon stream to a lower boiling point feed material

Life of this patent

Abstract

Claims16