Integrated process for the partial oxidation-thermal cracking of crude oil feedstocks

An integrated partial oxidation-thermal cracking process of increased yield for the utilization of all fractions of crude oil feedstocks in the concurrent production of synthesis gas and an olefin rich stream comprising the steps of:

• (a) separating, by distillation, a crude oil feedstock stream into distillate and asphaltic streams;
• (b) burning, at a temperature of about 1800.degree.-2200.degree. C., streams of fluid fuel and oxygen having a weight ratio of about 0.4-0.8 to 1 in the presence of superheated steam to form a reducing stream of hot combustion products;
• (c) passing said asphaltic stream as fuel to said burning step (b);
• (d) injecting a crude oil distillate fraction stream into said reducing stream of hot combustion products;
• (e) passing the resulting injected stream through a velocity accelerating zone to a reaction zone maintained at an exit temperature of about 800.degree.-1000.degree. C. and a pressure of about 10-150 psig for 5-50 milliseconds to effect thermal cracking of said crude oil distillate fraction stream to a stream containing stream and reaction products;
• (f) thermally quenching said steam and reaction products stream;
• (g) removing pitch from said stream and fractionating the resulting stream to provide at least one stream of hydrocarbon oil and an olefin rich gas stream;
• (h) recycling fractions of said hydrocarbon oil as fuel to said burning step (b);
• (i) separating carbon dioxide and any contained hydrogen sulfide from said olefin rich gas stream;
• (j) separating streams of synthesis gas, methane and ethylene from said olefin rich gas stream;
• and
• (k) recycling said methane stream as fuel to said burning step (b).