EP3904490A1 - Fissuration d'un régénérant riche en acétone de l'unité d'hydrogénation c4 rfcc en oléfines dans une colonne montante rfcc - Google Patents

Fissuration d'un régénérant riche en acétone de l'unité d'hydrogénation c4 rfcc en oléfines dans une colonne montante rfcc Download PDF

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EP3904490A1
EP3904490A1 EP20172241.0A EP20172241A EP3904490A1 EP 3904490 A1 EP3904490 A1 EP 3904490A1 EP 20172241 A EP20172241 A EP 20172241A EP 3904490 A1 EP3904490 A1 EP 3904490A1
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Prior art keywords
hydrocarbon stream
oxygenate
hydrocarbon
naphtha
fccu
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German (de)
English (en)
Inventor
Syed Basheer UMAR
Abdulmajeed AL KATHEERI
Abraham George
Joshua Moses
Abdulhamid CHAUDRY
Stephane Morin
Mohamed AL MUSHARFY
Mikael Berthod
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Adnoc Refining Research Centre
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Adnoc Refining Research Centre
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G11/14—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts
    • C10G11/18—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts according to the "fluidised-bed" technique
    • C10G11/182—Regeneration
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G21/00—Refining of hydrocarbon oils, in the absence of hydrogen, by extraction with selective solvents
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G3/00—Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids
    • C10G3/42—Catalytic treatment
    • C10G3/44—Catalytic treatment characterised by the catalyst used
    • C10G3/48—Catalytic treatment characterised by the catalyst used further characterised by the catalyst support
    • C10G3/49—Catalytic treatment characterised by the catalyst used further characterised by the catalyst support containing crystalline aluminosilicates, e.g. molecular sieves
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G3/00—Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids
    • C10G3/54—Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids characterised by the catalytic bed
    • C10G3/55—Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids characterised by the catalytic bed with moving solid particles, e.g. moving beds
    • C10G3/57—Production of liquid hydrocarbon mixtures from oxygen-containing organic materials, e.g. fatty oils, fatty acids characterised by the catalytic bed with moving solid particles, e.g. moving beds according to the fluidised bed technique
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G53/00—Treatment of hydrocarbon oils, in the absence of hydrogen, by two or more refining processes
    • C10G53/02—Treatment of hydrocarbon oils, in the absence of hydrogen, by two or more refining processes plural serial stages only
    • C10G53/08—Treatment of hydrocarbon oils, in the absence of hydrogen, by two or more refining processes plural serial stages only including at least one sorption step
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G55/00—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process
    • C10G55/02—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process plural serial stages only
    • C10G55/06—Treatment of hydrocarbon oils, in the absence of hydrogen, by at least one refining process and at least one cracking process plural serial stages only including at least one catalytic cracking step
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10—Feedstock materials
    • C10G2300/107—Atmospheric residues having a boiling point of at least about 538 °C
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10—Feedstock materials
    • C10G2300/1074—Vacuum distillates
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10—Feedstock materials
    • C10G2300/1077—Vacuum residues
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/40—Characteristics of the process deviating from typical ways of processing
    • C10G2300/4081—Recycling aspects
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/02—Gasoline

Definitions

  • the present invention relates to the field of petroleum refining, specifically fluid catalytic cracking of atmospheric residue and oxygenate-to-olefin conversion for oxygenate removal from hydrocarbon streams.
  • Important oil refining processes are, for example, distillation, vacuum distillation, catalytic reforming, catalytic cracking, alkylation, isomerization and hydrotreating.
  • Economically important products are, inter alia, C 2 - to C 4 -hydrocarbons such as, for example, ethylene, propylene, butane, isobutane, C 4 -olefins, gasoline, kerosene-type jet fuel, such as Jet A1, and Diesel.
  • FCC fluid catalytic cracking
  • long chain molecules of the feedstock are cracked into shorter chain molecules.
  • FCC allows for conversion of high-boiling, high-molecular weight hydrocarbon fractions of petroleum crude oils into more valuable gasoline, C 3 - and C 4 -olefinic gases, and other products.
  • FCC provides for approximately 30 % of the worldwide propylene production.
  • the typical feedstock for FCC is a fraction from crude oil having an initial boiling point of 340 °C or higher at atmospheric pressure and having a final boiling point of 520 to 540 °C with an average molecular weight ranging from about 200 to 600 or higher. This portion of crude oil is often referred to as heavy vacuum gas oil (HVGO).
  • HVGO heavy vacuum gas oil
  • a typical FCC process involves various reactions like cracking, e.g. thermal or, more importantly, catalytic cracking, hydrogen transfer, isomerization and condensation reactions.
  • catalytic cracking requires a catalyst, which provides for higher selectivity and better product control than thermal cracking.
  • the choice of reaction conditions and catalysts is crucial for the outcome of the process, i.e. conversion, selectivity and yields. For example, at higher reaction temperatures the yield of liquefied petroleum gas (LPG) is higher, but also the amount of undesired side-products, such as coke and dry gas. Also, the choice of the specific catalyst system determines selectivity towards specific products.
  • zeolites microporous aluminosilicate minerals
  • a prominent example thereof is "ultra-stable" zeolite Y (USY), an acidic zeolite allowing for high olefin selectivity.
  • USY ultra-stable zeolite Y
  • Another example is a zeolite of the pentasil family, e.g. ZSM-5, which is only able to crack C 5 - to C 7 -olefins and thus known to provide for LPG and increased propylene production. Therefore, combinations of different zeolite catalysts may be employed in order to improve selectivity towards the desired product.
  • a fluid catalytic cracking unit comprises a reactor section and a regenerator section.
  • the catalytic cracking of the petroleum feedstock takes place, wherein the chemical reactions are facilitated by a catalyst.
  • the catalyst becomes less active due to the formation of undesired side-products such as coke, fuel gas, and slurry oil.
  • coke deactivates the catalyst over time.
  • the catalyst In order to provide for high conversion of the feedstock, the catalyst needs to be regenerated regularly. Therefore, the catalyst is circulated between the reactor section and the regenerator section. During regeneration in the regenerator section, coke is burnt off the catalyst under oxygen-containing atmosphere (typically by using air) at high temperatures. After regeneration, the hot catalyst is cycled back from the regenerator section to the reactor section. This way, heat for the cracking process is supplied by the hot regenerated catalyst.
  • Residue Fluid Catalytic Cracking processes receive as hydrocarbon feed atmospheric residue (AR) which has initial boiling point of 340 °C or higher at atmospheric pressure and/or vacuum residue (VR) which has initial boiling point of 520 to 540 °C or higher at atmospheric pressure having a Conradson Carbon Residue (CCR) of more than 2 wt.-%.
  • hydrocarbon feeds for FCC such as HVGO have a CCR of less than 1 wt.-%.
  • Such high relative amounts of CCR in the RFCC hydrocarbon feeds necessitate means for and process steps of burning additional carbon expected in the regenerator side.
  • the RFCC operating conditions depend on the desired products: E.g.
  • RFCC operating conditions will be less severe (500 to 520 °C) compared to the propylene mode requiring more severe operating conditions (550 to 620 °C).
  • an additional external riser may be used to crack light cracked naphtha from RFCC units.
  • These processes are commercially called by different names, e.g. "Down-flow High Severity- Fluid Catalytic Cracking" or “Dual riser High Propylene Residue Fluid Catalytic Cracking".
  • burning coke in the regenerator section has been optimized by implementing a two-stage regenerator design in order to minimize catalyst deactivation in the presence of high metal loading on the catalyst.
  • temperature control i.e. control of heat transfer between the regenerator section and the reactor section has been improved, comprising a primary riser reactor and a secondary riser reactor.
  • reaction conditions employed for propylene mode FCC and/or RFCC imply high reaction temperatures of about 550 to 650 °C, i.e. higher reaction temperatures than in conventional gasoline FCC processes having reaction temperatures of about 500 to 510°C.
  • cracked olefinic naphtha may be fed to the same riser and/or different riser with higher reactor temperature.
  • Such high temperatures also lead to thermal cracking of hydrocarbons as side reactions to catalytic cracking, resulting in higher yields of undesired products such as dry gas and coke.
  • These negative side effects may be mitigated by down-flow high severity fluid catalytic cracking or high propylene mode RFCC, providing short contact times such as less than 0.5 seconds of the feed and desired products in the reactor.
  • reactor systems for RFCC and particularly for high propylene mode -RFCC have been provided in a two-stage design.
  • such two-stage RFCC process units comprise a reactor section comprising a primary riser reactor and a secondary riser reactor and two stages of regenerators.
  • the heat balance of the RFCC reactor system can be controlled as heat from the regenerator section may be used for the chemical reaction in the reactor section and transferred via the circulating catalyst.
  • a two-stage reactor section comprising a primary riser reactor and a secondary riser reactor the outlet temperatures of the primary and secondary risers usually are different.
  • the two-stage design allows for better control of reaction conditions, specifically temperatures, and, concurrently, more selective reaction conditions and thus higher yields of desired products. This is particularly beneficial for conversion of inferior feedstocks such as heavy crude oils or atmospheric residue to light olefins such as propylene.
  • the products obtained from a FCC process such as RFCC and high propylene mode RFCC, including diesel, gasoline and liquefied petroleum gas (LPG) may be further processed in downstream processing units of a reactor system.
  • FCC process such as RFCC and high propylene mode RFCC, including diesel, gasoline and liquefied petroleum gas (LPG)
  • LPG liquefied petroleum gas
  • branched C 4 -hydrocarbon and linear C 4 -hydrocarbon fractions can be obtained from mixed C 4 -hydrocarbon streams.
  • the branched C 4 -hydrocarbon fraction is rich in isobutylene and the linear C 4 -hydrocarbon fraction is rich in 2-butene.
  • the linear C 4 -hydrocarbon fraction may be directly passed to an alkylation unit for production of alkylates such as alkylated iso-octane
  • the linear C 4 -hydrocarbon fraction usually is passed to an olefin conversion unit, wherein the linear C 4 -hydrocarbons (2-butene) and ethylene are converted into propylene.
  • the unreacted C 4 -hydrocarbons from the olefin conversion unit are also passed on to the alkylation unit to produce alkylates.
  • the catalyst circulates between the at least one reactor (usually primary and secondary riser reactor) and the regenerator, oxygen used for catalyst regeneration may be entrained in the reactor, in particular in case of high catalyst circulation rates as typically used in high severity operation of residue fluid catalytic cracking.
  • oxygen used for catalyst regeneration may be entrained in the reactor, in particular in case of high catalyst circulation rates as typically used in high severity operation of residue fluid catalytic cracking.
  • the presence of oxygen in the reactor leads to undesired side reactions, e.g. the conversion of olefins to oxygenates.
  • FCC and RFCC units provide for high yields for propylene greater than 12 w.t.-% and for C 4 -olefins in the range of 10 to 14 w.t.-%, acetone is formed due to the presence of oxygen.
  • acetone is further promoted by the usually high metal loads of the catalysts and long residence times (contact times) of the substrates, i.e. the olefins, with the catalysts.
  • the formation of acetone in the reactor leads to increased acetone levels in the range of 200 to 1000 ppmw in the effluent streams of the reactor, such as the LPG and/or C 4 -hydrocarbon streams.
  • Such high acetone levels in the LPG and/or C 4 -hydrocarbon streams may cause corrosion in downstream units, e.g. acid alkylation reactors.
  • high acetone levels in the LPG and/or C 4 -hydrocarbon stream may also cause acetone absorption in the so-called "sulfur guard bed" located downstream of a C 4 -hydrocarbons preparation unit.
  • sulfur guard beds are sorbents providing for sorption of sulfur and/or sulfur compounds in order to prevent "slippage" of sulfur and/or sulfur compounds to further downstream olefin conversion units where it may contaminate and consequently also deactivate the noble metal catalyst.
  • acetone may be absorbed by the sulfur guard bed, and, thus, compete with sulfur and/or sulfur compounds for absorption.
  • the presence of acetone in the LPG and/or C 4 -hydrocarbon stream disadvantageously leads to slippage of sulfur and/or sulfur compounds to further downstream olefin conversion units and consequently also to contamination and even deactivation of the noble metal catalysts used therein.
  • acetone absorbed by the sorbent of the sulfur guard bed may be washed out and absorbed by a regenerant used for removal of sulfur from the sulfur guard bed in the first place.
  • a regenerant hydro-treated naphtha is used, which will upon absorption of acetone from the sorbent of the sulfur guard bed, also comprise acetone.
  • the acetone levels in the regenerant may be in the range of 2000 to 5000 ppmw.
  • the entrained acetone in the regenerant also negatively affects the naphtha pool product specifications.
  • oxygenate-to-olefin conversion processes include, for example, the conversion of methanol and/or dimethyl ether to C 2 - and C 3 -olefins like ethylene or propylene.
  • Such processes usually afford specific zeolites such as ZSM-22, ZSM-23, ZSM-34 and/or SAPO-34.
  • US 7,232,936 B1 describes a system and process for producing olefins, particularly ethylene and propylene, from oxygenates, e.g., methanol or dimethyl ether, in a fluidized bed reaction zone and using a molecular sieve catalyst such as ZSM-34 or SAPO-34 providing for higher ethylene selectivity.
  • WO 2001/062689 A1 describes a process for producing olefins from oxygenate in a reactor using molecular sieve catalysts such as ZSM-34 and SAPO-34. This process increases the olefin yield and selectivity. It is also described that unreacted feeds, e.g.
  • dimethyl ether can be recycled within the oxygenate-to-olefin reactor to the fluidized bed reaction zone.
  • the known processes employ oxygenates as the only or main feedstock for producing olefins.
  • the described oxygenate-to-olefin conversion processes are, however, not designed to convert oxygenates, specifically low amounts of oxygenates or impurities of oxygenates, in FCC reactor systems, in particular not for converting acetone comprised in a recycled hydrocarbon stream passed from a downstream processing unit to an upstream FCC reactor, in particular an upstream high propylene mode RFCC reactor.
  • an absorbent e.g. provided in the form of a bed of molecular sieves
  • an absorbent e.g. provided in the form of a bed of molecular sieves
  • molecular sieves may be used to remove acetone from a hydrocarbon streams.
  • Using molecular sieves is disadvantageous because the molecular sieve needs to be regenerated from time to time or even replaced entirely. This, however, disadvantageously requires interruption of the production process and, thus, also is expensive.
  • Another approach for acetone removal from hydrocarbon streams is described in Wo 2015/088816 A1 , wherein acetone is removed via washing an acetone-containing hydrocarbon stream with water.
  • the present invention solves the shortcomings of the prior art by providing a fluid catalytic cracking process, comprising the step(s) of:
  • the present invention relates to a reactor system for fluidic catalytic cracking comprising
  • the present invention relates to use of a process or reactor system according to any one of the preceding claims for producing one or more hydrocarbon product streams 4 .
  • the process, reactor system and use according to the present invention provide for the conversion of an acetone rich naphtha stream to olefins and, thus, for reducing the negative impact of acetone on the chemical grade naphtha specifications while at the same time reaction conditions efficient for both oxygenate-to-olefin conversions and fluid catalytic cracking are provided.
  • naphtha (or petroleum naphtha) as used in context of the present invention relates to a mixture of hydrocarbons, specifically an intermediate hydrocarbon liquid stream derived from the refining of crude oil.
  • Naphtha predominantly comprises or essentially consists of hydrocarbons having carbon numbers in the range of C 5 to C 6 and initial boiling points in the range of approximately 100°C to 200°C and has the CAS-no 232-443-2 .
  • Naphtha may also relate to both "heavy straight-run naphtha" and "full-range straight-run naphtha”.
  • Heavy straight-run naphtha predominantly comprises or essentially consists of hydrocarbons having carbon numbers in the range of C 6 to C 12 and initial boiling points in the range of approximately 65°C to 230°C and has the CAS-no 64742-41-9 (cf. definition by the European Chemical Agency provided at the website https://echa.europa.eu/de/substance-information/-/substanceinfo/100.059.110).
  • Full straight-run naphtha predominantly comprises or essentially consists of hydrocarbons having carbon numbers in the range of C 4 to C 11 and initial boiling points in the range of approximately minus 20°C to 220°C and has the CAS-no 64742-42-0 (cf. definition by the European Chemical Agency provided at the website https://echa.europa.eu/de/substance- information/-/substanceinfo/100.059.111).
  • hydro-treated naphtha as used in context of the present invention relates to heavy and light hydro-treated naphtha, i.e. mixtures comprising hydrocarbons obtained by treating a petroleum fraction with hydrogen in the presence of a catalyst.
  • "Heavy hydro-treated naphtha” predominantly comprises or essentially consists of hydrocarbons having carbon numbers in the range of C 6 to C 13 and initial boiling points in the range of approximately 65°C to 230°C and has the CAS-no 64742-48-9 (cf. definition by the European Chemical Agency provided at the website https://echa.europa.eu/de/substance-information/-/substanceinfo/100.059.210).
  • Light hydro-treated naphtha predominantly comprises or essentially consists of hydrocarbons having carbon numbers in the range C 4 to C 11 and initial boiling points in the range of approximately minus 20°C to 190°C and has the CAS-no 64742-49-0 (cf. definition by the European Chemical Agency provided at the website https://echa.europa.eu/de/substance-information/-/substanceinfo/100.059.211).
  • the term "whole cracked naphtha” as used in context of the present invention relates to heavy and light cracked naphtha, i.e. mixtures comprising hydrocarbons, specifically olefins, obtained from catalytically cracked naphthas.
  • "Heavy cracked naphtha” predominantly comprises or essentially consists of hydrocarbons having carbon numbers in the range of C 6 to C 12 and initial boiling points in the range of approximately 65°C to 230°C (148°F to 446°F). It contains a relatively large proportion of unsaturated hydrocarbons and has the CAS-no 64741-54-4 (cf. definition by the European Chemical Agency provided at the website https://echa.europa.eu/de/substance-information/-/substanceinfo/100.059.123).
  • Light cracked naphtha predominantly comprises or essentially consists of hydrocarbons having carbon numbers in the range of C 4 to C 11 and initial boiling points in the range of approximately minus 20°C to 190°C. It contains a relatively large proportion of unsaturated hydrocarbons and has the CAS-no 64741-55-5 (cf. definition by the European Chemical Agency provided at the website https://echa.europa.eu/de/substance-information/-/substanceinfo/100.059.124).
  • Atmospheric residue as used in context of the present invention relates to complex mixtures of hydrocarbons, specifically residuum from atmospheric distillation of crude oil. Atmospheric residue predominantly comprises or essentially consists of hydrocarbons having carbon numbers greater than C 11 and initial boiling points above approximately 200°C. Atmospheric residue commonly comprises 5 wt.% or more of 4-to 6-membered condensed ring aromatic hydrocarbons and has CAS-no 68333-22-2 (cf. definition by the European Chemical Agency provided at the website https://echa.europa.eu/de/substance-information/-/substanceinfo/100.063.414).
  • LPG Liquefied Petroleum Gas
  • LPG predominantly comprises or essentially consists of hydrocarbons having carbon numbers in the range of C 3 to C 7 and initial boiling points in the range of approximately minus 40°C to 80°C.
  • LPG commonly comprises one or more C 3 - and/or C 4 -hydrocarbons such as propane, propylene, butane, butylene and mixtures thereof.
  • LPG has the CAS-no 68476-85-7 (cf. definition by the European Chemical Agency provided at the website https://echa.europa.eu/de/substance-information/- /substanceinfo/100.064.257).
  • Naphthenic acids as used in context of the present invention relates to hydrocarbon mixtures from the acidic fraction of refined crude oil.
  • Naphthenic acids are a mixture of several cyclopentyl and cyclohexyl carboxylic acids with molecular weight of 120 to well over 700 atomic mass units.
  • the main fraction of Naphthenic acids predominantly comprises or essentially consists of hydrocarbons, specifically carboxylic acids, having carbon numbers in the range of C 8 to C 20 and initial boiling points in the range of approximately 140°C to 370°C.
  • Naphthenic acids is also used in a more generic sense for all carboxylic acids present in petroleum, whether cyclic, acyclic, or aromatic compounds, and carboxylic acids containing heteroatoms such as N and S. Naphthenic acids are assigned the CAS-no 1338-24-5 .
  • Zeolites and or molecular sieves are characterized by various three-dimensional molecular framework having a high degree of regularity and uniform size. The three-dimensional structure allows for selectively sorting molecules according to their molecular size via a size exclusion process. The maximum size of the molecular or ionic species that can enter the pores of a zeolite is controlled by the dimensions of the pores and channels.
  • Zeolites are widely used as catalysts in the petrochemical industry, for instance in fluid catalytic cracking and hydrocracking. Zeolites confine molecules in small spaces and thereby affect the confined molecules structure and reactivity. For example, zeolites, in particular the acidic forms of zeolites, facilitate acid-catalyzed reactions, such as isomerization, alkylation, and cracking.
  • equilibrium catalyst as used in context of the present invention relates to a physical mixture of varying proportions of fresh catalyst and regenerated catalyst circulating within a fluid catalytic cracking unit between the FCC unit's regenerator and reactor sections.
  • Fluid catalytic cracking process may be characterized by several parameters, such as the catalyst-to-oil ratio.
  • the term "catalyst-to-oil ratio" as used in context of the present invention refers to the amount of a catalyst relative to the amount of oil in the reaction zone of a reactor.
  • the catalyst-to-oil ratio affects the outcome of a reaction, specifically the selectivity towards specific products and yield thereof. For example, increasing the catalyst-to-oil ratio improves selectivity and conversion by enhancing catalytic reactions over thermal reactions.
  • high catalyst-to-oil ratios usually provide for increased selectivity towards propylene and also improved yields thereof.
  • the present invention relates to a fluid catalytic cracking process for producing one or more hydrocarbon product streams 4 from a first hydrocarbon stream 1 comprising a petroleum feedstock and a second hydrocarbon stream 2 comprising an oxygenate.
  • the present invention relates to a reactor system for fluidic catalytic cracking, comprising at least one fluidic catalytic cracking process unit (FCCU) 3 being arranged such that a first hydrocarbon stream 1 comprising a petroleum feedstock can be fed into the FCCU 3 and at least one C 4 -hydrocarbons preparation unit 6 producing a second hydrocarbon stream 2 comprising an oxygenate, wherein the reactor system is arranged such that the second hydrocarbon stream 2 can be passed from the at least one C 4 -hydrocarbons preparation unit 6 to (i) the at least one FCCU 3 , and/or (ii) into the first hydrocarbon stream 1 .
  • the present invention relates to use of a process or reactor system according to the present invention for producing one or more hydrocarbon product streams 4 .
  • a first embodiment according to the present invention relates to a fluid catalytic cracking process, comprising the step(s) of: (a) feeding a first hydrocarbon stream 1 comprising a petroleum feedstock and a second hydrocarbon stream 2 comprising an oxygenate to a fluid catalytic cracking process unit (FCCU) 3 for producing one or more hydrocarbon product stream(s) 4 from the first hydrocarbon stream 1 and the second hydrocarbon stream 2 .
  • FCCU fluid catalytic cracking process unit
  • the first hydrocarbon stream 1 and the second hydrocarbon stream 2 are fed separately to the FCCU 3 .
  • This allows for an improved control of feeding the first hydrocarbon stream 1 and the second hydrocarbon stream 2 to the FCCU 3 .
  • the hydrocarbon stream 1 is fed to the FCCU 3 before or subsequent to hydrocarbon stream 2 , preferably, the hydrocarbon stream 1 is fed to the FCCU 3 subsequent to hydrocarbon stream 2 .
  • the process of the present invention provides for a high flexibility at which stage and in what admixtures the first and second streams are fed to the fluid catalytic cracking unit.
  • the second hydrocarbon stream 2 comprises naphtha. This way, both the oxygenate and the naphtha comprised by the second hydrocarbon stream 2 are converted in the FCCU 3 .
  • the process comprises the step of (b) passing the one or more hydrocarbon product stream(s) 4 to one or more downstream process units 5 . This provides for further processing of the one or more hydrocarbon product stream(s) 4 to value-added petroleum products.
  • At least one of the one or more downstream process units 5 is a C 4 -hydrocarbons preparation unit 6 comprising a sorbent for sorbing the oxygenate and/or sulfur and/or sulfur compounds.
  • Sulfur and/or sulfur compounds may be, for example, elemental sulfur, hydrogen sulfide (H2S), or organosulfur compounds like thiols (mercaptans), alkyl sulfides and/or alkyl disulfides.
  • H2S hydrogen sulfide
  • organosulfur compounds like thiols (mercaptans), alkyl sulfides and/or alkyl disulfides.
  • the process comprises the step of (c) feeding a third hydrocarbon stream 7 comprising naphtha to the one or more downstream process units (5), preferably to the C 4 -hydrocarbons preparation unit 6, for collecting the oxygenate and/or sulfur and/or sulfur compounds present in the C 4 -hydrocarbons preparation unit 6 and forming a fourth hydrocarbon stream 8 comprising the oxygenate and/or sulfur and/or sulfur compounds and the naphtha.
  • the sorbent will not get saturated by the oxygenate and maintains its sulfur sorbing capacity. Specifically, this provides for the prevention of any sulfur slippage to downstream process units and catalyst damages. Additionally, also the quality of the final hydrocarbon products is increased as slippage of oxygenate from the sorbent into the final hydrocarbon products is prevented.
  • the process further comprises the step of (d2) passing the fourth hydrocarbon stream 8 from the one or more downstream process units 5 to the FCCU 3 .
  • the second hydrocarbon stream 2 is the fourth hydrocarbon stream 8.
  • This provides for recycling the naphtha used for regeneration of the C 4 -hydrocarbons preparation unit 6.
  • both the oxygenate and the naphtha used for regeneration the C 4 -hydrocarbons preparation unit 6 can be converted to olefins within the FCCU 3 .
  • this provides for a more efficient overall process.
  • H 2 S will be absorbed by an off-gas amine absorber and/or an LPG amine absorber and the un-converted sulfur compounds like mercaptans will be extracted using caustic soda, for example, in an LPG extraction unit or mercaptan oxidation unit.
  • This allows for efficient removal of sulfur and/or sulfur compounds from the one or more one or more hydrocarbon product stream(s) 4 . This way, accumulation of sulfur and/or sulfur compounds during the overall process is prevented.
  • the oxygenate is at least one oxygenate selected from the group consisting of alcohols, aldehydes, ketones, ethers, carbonic acids, esters, anhydrides and/or any combination thereof, preferably, wherein the oxygenate is one or more ketones, more preferably, one or more ketones selected from the group consisting of acetone, dimethyl ketone, propanone, methyl ethyl ketone, diethyl ketone, diphenyl ketone, benzophenone, methyl phenyl ketone, acetophenone, most preferably, wherein the oxygenate is acetone.
  • the second hydrocarbon stream 2 comprises the oxygenate in a mass fraction of at least 10 ppmw, preferably of at least 100 ppmw, more preferably of at least 200, even more preferably of at least 350 ppmw, most preferably of at least 390 ppmw, and/or in a mass fraction of at most 1000 ppmw, preferably at most 600 ppmw, more preferably of at most 500 ppmw, even more preferably of at most 450 ppmw, most preferably of at most 410 ppmw.
  • the oxygenate is present in the second hydrocarbon stream 2 in a mass fraction between 10 - 1000 ppmw, preferably between 100 - 600 ppmw, more preferably between 200 - 500 ppmw, even more preferably between 350 - 450 ppmw, most preferably between 390 - 410 ppmw.
  • the oxygenate-to-olefin conversion reaction is operated close to thermodynamic equilibrium. This provides for a slow reaction rate of the oxygenate-to-olefin conversion reaction while the desired catalytic cracking reactions are fast. This allows for faster conversion of the petroleum feedstock in the fluid catalytic cracking process.
  • the naphtha is selected from hydro-treated naphtha, whole cracked naphtha and/or combinations thereof, more preferably a combination of hydro-treated naphtha and whole cracked naphtha, even more preferably regenerant naphtha, most preferably unreacted regenerant naphtha.
  • the second hydrocarbon stream 2 comprises acetone and hydro-treated naphtha, preferably, wherein the second hydrocarbon stream 2 essentially consists of acetone and hydro-treated naphtha.
  • the second hydrocarbon stream 2 comprises acetone, hydro-treated naphtha, and whole cracked naphtha, preferably, wherein the second hydrocarbon stream 2 essentially consists of acetone hydro-treated naphtha, and whole cracked naphtha.
  • the second hydrocarbon stream 2 comprises acetone and regenerant naphtha, preferably, the second hydrocarbon stream 2 essentially consists of acetone and regenerant naphtha. This provides for efficient removal of acetone from the C 4 -hydrocarbons preparation unit 6.
  • the process further comprises after step(a) the step of converting the oxygenate to olefins by contacting the second hydrocarbon stream 2 with an oxygenate-to-olefin conversion molecular sieve catalyst under oxygenate-to-olefin conversion conditions.
  • the second hydrocarbon stream 2 comprises the oxygenate in such amounts that the oxygenate-to-olefin conversion reaction is operated at or close to thermodynamic equilibrium. This provides for a slow reaction rate of the oxygenate-to-olefin conversion reaction while the desired fluid catalytic cracking reactions are fast. In other words, these process conditions allow for both oxygenate-to-olefin conversion and fast catalytic cracking of the petroleum feedstock at the same time.
  • the oxygenate-to-olefin conversion molecular sieve catalyst is the oxygenate-to-olefin conversion molecular sieve catalyst
  • the oxygenate-to-olefin conversion molecular sieve catalyst is an equilibrium fluid catalytic cracking catalyst. This allows for maintaining a high activity of the catalyst and consequently also for a high conversion of feedstock. Also, this allows for temperature control and heat transfer within sections of the fluid catalytic cracking process unit, i.e. the regenerator section and the reactor section.
  • the oxygenate-to-olefin conversion molecular sieve catalyst comprises one or more microporous aluminosilicate minerals (zeolites), preferably, one or more zeolites selected from the group consisting of zeolite Y, sodium-free zeolite Y, rare-earth metal ion-exchanged zeolites, ultra-stable zeolite Y, pentasil-zeolites, most preferably, ultra-stable zeolite Y (“USY”) and ZSM-5.
  • zeolites microporous aluminosilicate minerals
  • the combination of USY zeolite and ZSM-5 comprises USY zeolite in a relative weight amount based on the total weight of the olefin conversion molecular sieve catalyst of at least 70 w.t.-%, preferably of at least 80 w.t.-%, more preferably of at least 85 w.t.-%, even more preferably of at least 89 w.t.-% most preferably of at least 89.5 w.t.-% and/or of at most 99.9 w.t.-%, preferably of at most 99 w.t.-%, more preferably of at most 95 w.t.-%, even more preferably of at most 91 w.t.-% , most preferably of at most 90.5 w.t.-%.
  • the combination of USY zeolite and ZSM-5 comprises USY zeolite in a relative weight amount based on the total weight of the olefin conversion molecular sieve catalyst of between 70 - 99.9 w.t.-%, preferably between 80 - 99 w.t.-%, more preferably between 85 - 95 w.t.-%, even more preferably between 89 - 91 w.t.-%, most preferably between 89.5 - 90.5 w.t.-%.
  • the combination of USY zeolite and ZSM-5 comprises ZSM-5 in a relative weight amount based on the total weight of the olefin conversion molecular sieve catalyst at least 0.1 w.t.-%, preferably of at least 1 w.t.-%, more preferably of at least 5 w.t.-%, even more preferably of at least 9 w.t.-% most preferably of at least 9.5 w.t.-% and/or of at most 30 w.t.-%, preferably of at most 20 w.t.-%, more preferably of at most 15 w.t.-%, even more preferably of at most 11 w.t.-% , most preferably of at most 10.5 w.t.-%.
  • the combination of USY zeolite and ZSM-5 comprises ZSM-5 in a relative weight amount based on the total weight of the olefin conversion molecular sieve catalyst of between 0.1 - 30 w.t.-%, preferably between 1 - 20 w.t.-%, more preferably between 5 - 15 w.t.-%, even more preferably between 9 - 11 w.t.-%, most preferably between 9.5 - 10.5 w.t.-%.
  • the process according to the present invention allows for an improve selectivity towards the desired product, such as propylene.
  • the oxygenate-to-olefin conversion molecular sieve catalyst comprises one or more further components selected from the group consisting of matrix, binder, filler and/or any combination thereof.
  • the oxygenate-to-olefin conversion molecular sieve catalyst comprises one or more metals or metal-based compounds, preferably wherein the metals or the metal-based compounds are nickel and/or vanadium and/or nickel-based compounds and/or vanadium-based compounds and/or any mixture thereof.
  • Nickel and vanadium provide for high reactivities and good selectivities in the processed involved in olefin-to-acetone and/or acetone-to-olefin conversion.
  • the oxygenate-to-olefin conversion molecular sieve catalyst comprises one or more metals or metal-based compounds, preferably nickel and/or vanadium and/or nickel-based compounds and/or vanadium-based compounds, in a combined mass fraction of all one or more metals or metal-based compounds of at least 1000 ppmw, preferably of at least 2000 ppmw, more preferably of at least 4000, even more preferably of at least 4900 ppmw, most preferably of at least 4950 ppmw, and/or in an mass fraction of at most 9000 ppmw, preferably at most 8000 ppmw, more preferably of at most 6000 ppmw, even more preferably of at most 5100 ppmw, most preferably of at most 5050 ppmw.
  • the oxygenate-to-olefin conversion molecular sieve catalyst comprises one or more metals or metal-based compounds, preferably nickel and/or vanadium and/or nickel-based compounds and/or vanadium-based compounds, in a combined mass fraction of all one or more metals or metal-based compounds of between 1000 - 9000 ppmw, preferably between 2000 - 8000 ppmw, more preferably between 4000 - 6000 ppmw, even more preferably between 4900 - 5100 ppmw, most preferably between 4950 - 5050 ppmw.
  • Such high metal loadings provide for high reactivities of the catalyst and, thus, high reaction rates and/or turn overs of reactions involved in olefin-to-acetone and/or acetone-to-olefin conversion.
  • the oxygenate to olefin conversion conditions comprise a reaction temperature of at least 500 °C, preferably of at least 510 °C, more preferably of at least 520 °C, even more preferably of at least 540 °C, most preferably of at least 550 °C and/or of at most 720 °C, preferably of at most 670 °C, more preferably of at most 650 °C, even more preferably of at most 630 °C, most preferably of at most 620 °C.
  • the reaction temperature is between 500 - 720 °C, preferably between 510 - 670 °C, more preferably between 520 - 650 °C, even more preferably between 540 - 630 °C, and most preferably between 550 - 620 °C.
  • the oxygenate to olefin conversion conditions comprise a reaction pressure which is slightly above atmospheric pressure.
  • the oxygenate to olefin conversion conditions are reaction conditions employed for fluid catalytic cracking, preferably, residue fluid catalytic cracking, more preferably high severity fluid catalytic cracking.
  • the present invention provides for efficient oxygenate to olefin conversion, while the chemical processes involved in fluid catalytic cracking are not negatively affected.
  • the present invention allows for efficient oxygenate-to-olefin conversion and fluid catalytic cracking at the same time.
  • the oxygenate to olefin conversion conditions are reaction conditions employed for fluid catalytic cracking (FCC), preferably, residue fluid catalytic cracking (RFCC), more preferably down-flow high severity FCC or high propylene mode residue fluid catalytic cracking.
  • FCC fluid catalytic cracking
  • RFCC residue fluid catalytic cracking
  • the petroleum feedstock is selected from the group consisting of traditional fluid catalytic cracking feedstocks, deeply deasphalted oil, vacuum residue, atmospheric residue and/or any combination thereof, preferably the petroleum feedstock is atmospheric residue.
  • the process of the present invention may be employed in conventional fluid catalytic cracking process units.
  • the one or more hydrocarbon product streams are provided.
  • Another embodiment according to the present invention relates to a process of any one of the preceding embodiments, wherein the one or more hydrocarbon product streams 4 comprise gasoline and LPG products, preferably one or more hydrocarbons selected from the group consisting of C 2 -hydrocarbons, C 3 -hydrocarbons, C 4 -hydrocarbons, liquified petroleum gas, whole cracked naphtha, hydro-treated naphtha and/or any combination thereof, preferably, wherein the one or more hydrocarbon product streams comprise propylene and/or alkylates.
  • the present invention provides for a wide range of product streams.
  • the process of the present invention is a continuous process. This provides for increased process efficiency and economic maintenance.
  • the process is characterized by a high catalyst-to-oil-ratio, preferably, wherein the high catalyst-to-oil-ratio in w.t.-%/ w.t.-% is at least 5, preferably at least 8, more preferably at least 12, even more preferably at least 17, most preferably at least 17.5 and/or at most 31, preferably at most 28, more preferably at most 24, even more preferably at most 19, and most preferably at most 18.5.
  • the high catalyst-to-oil-ratio in w.t.-%/ w.t.-% is between 5 - 31, preferably between 8 - 28, more preferably between 12 - 24, even more preferably between 17 - 19, and most preferably between 17.5 - 18.5.
  • Such high catalyst-to-oil-ratios mitigate negative effects of operating at high reaction temperatures and/or thermal cracking. Further, high catalyst-to-oil-ratios provide for improved selectivity by enhancing catalytic reaction over unselective thermal reactions.
  • reaction rate of the oxygenate-to-olefin conversion reaction is slower than the reaction rate of any of the reactions involved in the residue fluid catalytic cracking process.
  • a regenerant stream is fed to the C 4 -hydrocarbons preparation unit 7. This provides for regeneration of the C 4 -hydrocarbons preparation unit 7 in order to maintain high reactivity of the C 4 -hydrocarbons preparation unit 7.
  • the regenerant stream 8 collects any oxygenate present in the C 4 -hydrocarbons preparation unit 7 , preferably, wherein the oxygenate is sorbed by a sorbent for sorbing sulfur and/or sulfur compounds, more preferably, wherein the oxygenate is acetone.
  • the FCCU 3 is at least one residue fluid catalytic cracking process unit (RFCCU) and/or at least one down-flow high severity FCC or high propylene mode RFCC. This allows for conversion of a broad range of petroleum feedstocks and makes the claimed process versatile.
  • RRCCU residue fluid catalytic cracking process unit
  • the present invention relates to reactor system for fluidic catalytic cracking, comprising
  • the second hydrocarbon stream 2 is as specified in any one of the above-described embodiments.
  • each FCCU 3 comprises at least one reactor section and at least one regenerator section.
  • the at least one reactor section comprises at least one up-flow reactor, preferably two up-flow reactors.
  • the at least one reactor section comprises at least one up-flow reactor, preferably two up-flow reactors.
  • the second hydrocarbon stream 2 is fed to the at least one secondary riser.
  • the hydrocarbon stream 1 is fed to the at least one primary riser having at least two inlets before or subsequent to hydrocarbon stream 2 , preferably, the hydrocarbon stream 1 is fed to the at least one primary riser having at least two inlets subsequent to hydrocarbon stream 2 .
  • the reactor section of the FCCU 3 comprises a primary riser having at least two inlets.
  • the second hydrocarbon stream 2 is fed to the at least one primary riser having at least two inlets. Thereby, two different feed streams can be injected into the same primary riser.
  • the reactor section of the FCCU 3 comprises at least one primary riser, preferably at least one primary and at least one secondary riser.
  • heat transferred from the regenerator section to the reactor section can dissipate at different stages, i.e. a first portion of heat can dissipate in the first riser and subsequently a second portion of heat can dissipate in the second riser.
  • this provides for better control of process temperatures in different zones of the reactor.
  • This provides for increased yields of lighter olefins such as propylene.
  • the reactor section comprises an oxygenate-to-olefin conversion molecular sieve catalyst as specified in in any one of the above-described embodiments. This provides for efficient conversion of oxygenate to olefins.
  • the oxygenate-to-olefin conversion molecular sieve catalyst circulates between the reactor section and the regenerator section. This provides for efficient heat transfer between the regenerator section and the reactor section of the fluid catalytic process unit and provides heat necessary for the fluid catalytic cracking process and/or oxygenate-to-olefin conversion.
  • the C 4 -hydrocarbons preparation unit 6 comprises a sorbent for sorbing the oxygenate and/or sulfur and/or sulfur compounds. This way, contamination of downstream processing units, specifically contamination and damage of downstream catalysts is prevented. This also provides for less sulfur in desired hydrocarbon products and thus allows for higher quality products.
  • the reactor system further comprises at least one gas recovery unit.
  • a gas recovery unit may comprise, for example, an unsaturated gas plant 5a , an unsaturated liquefied petroleum (LPG) treatment 5b and/or propylene recovery 5c .
  • the reactor system further comprises at least one hydrogenation and/or isomerization unit.
  • the FCCU 3 is at least one residue fluid catalytic cracking process unit (RFCCU) and/or at least one down-flow high severity FCC or high propylene mode RFCC unit.
  • RRCCU residue fluid catalytic cracking process unit
  • FCC or high propylene mode RFCC unit This allows for conversion and processing of a broad range of petroleum feedstocks and intermediate products and makes the claimed reactor system suitable for producing versatile products.
  • the present invention relates to the use of a process or reactor system according to any one of the embodiments described above for producing one or more hydrocarbon product streams 4 .
  • the producing one or more hydrocarbon product streams 4 are as described in any one of the above embodiments.
  • This allows for conversion and processing of a broad range of petroleum feedstocks and intermediate products and makes the claimed reactor system suitable for producing versatile products.
  • this also allows for recycling of regenerant naphtha and provides for resource efficient operation of a reactor system for fluidic catalytic cracking.
  • This also allows for conversion of acetone to olefins. Concurrently, this also prevents corrosion of downstream process units and catalysts due to the prevention of oxygenate entrainment, specifically acetone entrainment.
  • the reaction rate of the oxygenate-to-olefin conversion is slow, allowing for faster conversion of the petroleum feedstock in the fluid catalytic cracking process.
  • FCC fluid catalyst cracking
  • ACE advanced cracking evaluation
  • the combination of USY zeolite and ZSM-5 comprises USY zeolite in a relative weight amount based on the total weight of the olefin conversion molecular sieve catalyst of between 89.5 - 90.5 w.t.-% and ZSM-5 in a relative weight amount based on the total weight of the olefin conversion molecular sieve catalyst of between 9.5 - 10.5 w.t.-%).
  • the FCC Catalyst had an equilibrium metal content of 5000 ppmw, wherein nickel and vanadium compounds were used.
  • the FCC Catalyst was used in a lab deactivated form, i.e. commercially available catalyst, having a similar metal content and activity as an already-in-use catalyst in an existing industrial plant.
  • a hydrocarbon mixture of 10 w.t.-% hydro-treated Naphtha and 90 w.t.-% whole cracked Naphtha having an acetone level of 400 ppmw was used as feed.
  • additional oxygen was added for simulating oxygen entrainment from the regenerator.
  • the standard deviation of 11% of experiments 2543, 2547, 2548, 2489 and 2490 indicates reproducibility of the observed results.

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EP20172241.0A 2020-04-30 2020-04-30 Fissuration d'un régénérant riche en acétone de l'unité d'hydrogénation c4 rfcc en oléfines dans une colonne montante rfcc Pending EP3904490A1 (fr)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4012455A (en) * 1974-07-31 1977-03-15 Mobil Oil Corporation Upgrading refinery light olefins with hydrogen contributor
US20140296593A1 (en) * 2013-03-28 2014-10-02 Shell Oil Company Process for the fluid catalytic cracking of oxygenated hydrocarbon compounds from biological origin
US20140357912A1 (en) * 2012-02-14 2014-12-04 Reliance Industries Limited Process for catalytic conversion of low value hydrocarbon streams to light olefins

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4012455A (en) * 1974-07-31 1977-03-15 Mobil Oil Corporation Upgrading refinery light olefins with hydrogen contributor
US20140357912A1 (en) * 2012-02-14 2014-12-04 Reliance Industries Limited Process for catalytic conversion of low value hydrocarbon streams to light olefins
US20140296593A1 (en) * 2013-03-28 2014-10-02 Shell Oil Company Process for the fluid catalytic cracking of oxygenated hydrocarbon compounds from biological origin

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
CHEMICAL ABSTRACTS, Columbus, Ohio, US; abstract no. 64742-49-0

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