# US 9,434,662 B2 · Integrated fluid catalytic cracking and alkylation process > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,434,662 B2 - Document ID: US9434662B2 - Status: Granted - Kind: B2 - Application number: 14/229,437 - Filed: 2014-03-28 - Published: 2015-10-01 - Granted: 2016-09-06 - Earliest claimed: 2014-03-28 - Assignees: Uop LLC - Applicants: Uop LLC - Inventors: Trung Pham; Susie C. Martins; Douglas A. Nafis - Web page: https://patentgrep.com/patent/US9434662B2 ## CPC - C07C 7/005: {Processes comprising at least two steps in series} - C07C 2/58: Catalytic processes - C07C 5/41: Catalytic processes - C10G 11/18: according to the "fluidised-bed" technique - C10G 45/58: to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins (C10G32/00 takes precedence; improving or increasing the octane number or aromatic content of naphtha C10G35/00) - C10G 45/68: Aromatisation of hydrocarbon oil fractions - C10G 69/04: including at least one step of catalytic cracking in the absence of hydrogen - C10G 69/123: {alkylation} - C10G 2300/1033: Oil well production fluids - C10G 2300/107: Atmospheric residues having a boiling point of at least about 538 °C - C10G 2400/02: Gasoline - C10G 2400/30: Aromatics - C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS - 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 ## Abstract An integrated hydrocarbon conversion process is described. The process includes contacting a heavy hydrocarbon feedstock with a hydrocarbon cracking catalyst in a fluidized reactor zone to produce light olefins to form a fluid catalytic cracker (FCC) effluent stream comprising a range of hydrocarbons. The FCC effluent stream is separated to form at least a stream rich in C4 hydrocarbons which comprises isobutane and 1-butene. The stream rich in C4 hydrocarbons is introduced into an alkylation reaction zone where the isobutane and the 1-butene are alkylated to form a reaction product mixture comprising dimethylhexanes and C9+ hydrocarbons. The reaction product mixture is dehydrocyclized to form a stream rich in xylenes. ## Claims ### Claim 1 An integrated fluid catalytic cracking (FCC) and alkylation process comprising: contacting a heavy hydrocarbon feedstock with an FCC catalyst in a fluidized reactor zone at effective conditions to produce an FCC effluent comprising light olefins and a range of hydrocarbons; separating the FCC effluent in a separation zone to obtain at least a C4-rich hydrocarbons stream comprising isobutane and 1-butene, a gasoline stream comprising aromatics, and a propylene stream; contacting the C4-rich hydrocarbons stream in an alkylation reaction zone with an alkylation catalyst under effective conditions to alkylate isobutane and 1-butene to produce a reaction product mixture comprising dimethylhexanes and C9+ hydrocarbons; contacting at least a portion of the reaction product mixture in an aromatization zone with a dehydrocyclization catalyst under effective conditions to produce a dehydrocyclization effluent stream comprising xylenes; introducing the dehydrocyclization effluent stream and at least a first portion of the gasoline stream to an aromatics separation zone to obtain a xylenes-rich stream and an alkylate stream comprising isoheptane and isooctane; mixing the alkylate stream with at least a second portion of the gasoline stream; and recovering the propylene stream. ### Claim 2 (depends on 1) The process of claim 1 further comprising: separating the reaction product mixture into a stream rich in dimethylhexanes and a stream rich in C9+ hydrocarbons before the step of contacting at least a portion of the reaction product mixture in an aromatization zone; and wherein the step of contacting at least a portion of the reaction product mixture in an aromatization zone with a dehydrocyclization catalyst under effective conditions to produce a dehydrocyclization effluent stream comprising xylenes comprises contacting the stream rich in dimethylhexanes in an aromatization zone to form the dehydrocyclization effluent stream comprising xylenes. ### Claim 3 (depends on 2) The process of claim 2 further comprising recycling the stream rich in C9+ hydrocarbons to the fluidized reactor zone. ### Claim 4 (depends on 2) The process of claim 2, further comprising: separating a light cycle oil stream from the FCC effluent stream; mixing at least a portion of the light cycle oil stream with the stream rich in C9+ hydrocarbons to form a mixed stream; and recycling the mixed stream to the fluidized reactor zone. ### Claim 5 (depends on 2) The process of claim 2 wherein the stream rich in dimethylhexane has a ratio of dimethylhexane to trimethylpentane of at least about 2:1. ### Claim 6 (depends on 2) The process of claim 2 further comprising: separating the gasoline stream into an aromatic fraction and a non-aromatic fraction; wherein the step of introducing at least the first portion of the gasoline stream into the aromatics separation zone comprises introducing the aromatic fraction into the aromatics separation zone; and wherein the step of mixing the alkylate stream from the aromatics separation zone with at least the second portion of the gasoline stream comprises mixing the alkylate stream from the aromatics separation zone with the non-aromatic fraction of the gasoline stream. ### Claim 7 (depends on 1) The process of claim 1 further comprising: hydrotreating the heavy hydrocarbon feedstock in a hydrotreating zone before contacting the heavy hydrocarbon feed with the FCC catalyst. ### Claim 8 (depends on 7) The process of claim 7, further comprising: separating a light cycle oil stream from the FCC effluent stream; and mixing at least a portion of the light cycle oil stream with the heavy hydrocarbon feedstock before hydrotreating the heavy hydrocarbon feedstock. ### Claim 9 (depends on 1) The process of claim 1 further comprising: introducing an isobutane-rich stream into the alkylation reaction zone. ### Claim 10 (depends on 9) The process of claim 9 wherein the isobutane-rich stream is produced by isomerizing a stream comprising n-butane. ### Claim 11 (depends on 1) The process of claim 1 wherein the alkylation catalyst comprises an ionic liquid catalyst. ### Claim 12 (depends on 1) The process of claim 1 wherein a ratio of isobutane to 1-butene in the alkylation zone is in a range of about 1:1 to about 50:1 by mole ratio. ### Claim 13 (depends on 1) The process of claim 1 wherein the C4-rich hydrocarbons stream contains less than about 50 wt % total of 2-butene and isobutene. ### Claim 14 (depends on 1) The process of claim 1, further comprising: separating a light cycle oil stream from the FCC effluent stream; mixing at least a portion of the light cycle oil stream with a second portion of the reaction product mixture to form a mixed stream; and recovering the mixed stream. ### Claim 15 An integrated fluid catalytic cracking (FCC) and alkylation process comprising: contacting a hydrotreated heavy hydrocarbon feedstock with an FCC catalyst in a fluidized reactor zone at effective conditions to produce an FCC effluent comprising light olefins and a range of hydrocarbons; separating the FCC effluent in a separation zone to obtain at least a C4-rich hydrocarbons stream comprising isobutane and 1-butene, a light cycle oil stream, a gasoline stream comprising aromatics, and a propylene stream; contacting the C4-rich hydrocarbons stream in an alkylation reaction zone with an alkylation catalyst under effective conditions to alkylate isobutane and 1-butene to produce a reaction product mixture comprising dimethylhexanes and C9+ hydrocarbons; separating the reaction product mixture into a dimethylhexanes-rich stream and a C9+ hydrocarbons-rich stream; contacting the dimethylhexanes-rich stream in an aromatization zone with a dehydrocyclization catalyst under an effective conditions to produce a dehydrocyclization effluent stream comprising xylenes; introducing the dehydrocyclization effluent stream and at least a first portion of the gasoline stream to an aromatics separation zone to obtain a xylenes-rich stream and an alkylate stream comprising isoheptane and isooctane; mixing the alkylate stream with at least a second portion of the gasoline stream; mixing at least a portion of the light cycle oil stream with the C9+ hydrocarbons-rich stream and recycling this mixed stream to the fluidized reactor zone; and recovering the propylene stream. ### Claim 16 (depends on 15) The process of claim 15, further comprising: separating the gasoline stream into an aromatic fraction and a non-aromatic fraction; wherein the step of introducing at least the first portion of the gasoline stream into the aromatics separation zone comprises introducing the aromatic fraction into the aromatics separation zone; and wherein the step of mixing the alkylate stream from the aromatics separation zone with at least the second portion of the gasoline stream comprises mixing the alkylate stream from the aromatics separation zone with the non-aromatic fraction of the gasoline stream.