Integrated slurry hydroprocessing and steam pyrolysis of crude oil to produce petrochemicals

An integrated slurry hydroprocessing and steam pyrolysis process for production of olefinic and aromatic petrochemicals from crude oil, the process comprising:

• a. treating the crude oil and residuals or bottoms derived from a heated stream within the steam pyrolysis zone, and optionally, one or more of slurry residue or a mixed product stream, in a slurry hydroprocessing zone in the presence of hydrogen under conditions effective to produce an effluent having an increased hydrogen content;
• b. thermally cracking hydroprocessed effluent by heating hydroprocessed effluent in a convection section of a steam pyrolysis zone, separating the heated hydroprocessed effluent into a vapor fraction and a liquid fraction, passing the vapor fraction to a pyrolysis section of a steam pyrolysis zone to produce a mixed product stream, and discharging the liquid fraction, wherein separating the heated hydroprocessed effluent is with a vapor-liquid separation device that includes
• a pre-rotational element having an entry portion and a transition portion, the entry portion having an inlet for receiving the 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 and a riser section at an upper end of the cyclonic member through which vapors pass, and
• a liquid collector/settling section through which the liquid phase passes prior to conveyance of all or a portion of said liquid phase to step (a);
• c. separating the mixed product stream;
• d. purifying hydrogen recovered in step (c) and recycling it to step (a);
• and
• e. recovering olefins and aromatics from the separated mixed product stream.

An integrated slurry hydroprocessing and steam pyrolysis process for production of olefinic and aromatic petrochemicals from crude oil, the process comprising:

• a. treating the crude oil and residuals or bottoms derived from one or more of slurry residue, a heated stream within the steam pyrolysis zone or a mixed product stream, in a slurry hydroprocessing zone in the presence of hydrogen under conditions effective to produce an effluent having an increased hydrogen content;
• b. thermally cracking the effluent in the presence of steam in a steam pyrolysis zone under conditions effective to produce the mixed product stream;
• c. separating the mixed product stream by
• compressing the thermally cracked mixed product stream with plural compression stages,
• subjecting the compressed thermally cracked mixed product stream to caustic treatment to produce a thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide,
• compressing the thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide,
• dehydrating the compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide,
• recovering hydrogen from the dehydrated compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide, and
• obtaining olefins and aromatics from the remainder of the dehydrated compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide;
• d. purifying recovered hydrogen from the dehydrated compressed thermally cracked mixed product stream with a reduced content of hydrogen sulfide and carbon dioxide and recycling it to step (a);
• and
• e. recovering olefins and aromatics from the separated mixed product stream.