Integrated hydroprocessing and fluid catalytic cracking for processing of a crude oil
An integrated hydroprocessing and fluid catalytic cracking process is provided for the direct processing of a crude oil to produce olefinic and aromatic petrochemicals. Crude oil and hydrogen are charged to a hydroprocessing zone operating under conditions effective to produce a hydroprocessed effluent having a reduced content of contaminants, an increased paraffinicity, reduced Bureau of Mines Correlation Index, and an increased American Petroleum Institute gravity. The hydroprocessed effluent is separated into a low boiling fraction and a high boiling fraction. The low boiling fraction is cracked in a first downflow reactor of a fluid catalytic cracking unit in the presence of a predetermined amount of catalyst to produce cracked products and spent catalyst, and the high boiling fraction is cracked in a second downflow reactor of the fluid catalytic cracking unit in the presence of a predetermined amount of catalyst to produce cracked products and spent catalyst. Spent catalyst from both the first and second downflow reactors are regenerated in a common regeneration zone, and first and second cracked product streams are recovered.
1. An integrated hydroprocessing and fluid catalytic cracking process for the direct processing of a crude oil to produce olefinic and aromatic petrochemicals, the process comprising:
a. charging the crude oil and hydrogen to a hydroprocessing zone operating under conditions effective to produce a hydroprocessed effluent having a reduced content of contaminants, an increased paraffinicity and an increased American Petroleum Institute gravity;
b. separating the hydroprocessed effluent into a low boiling fraction and a high boiling fraction;
c. cracking the low boiling fraction in a first downflow reactor of a fluid catalytic cracking unit in the presence of a predetermined amount of catalyst to produce cracked products and spent catalyst;
d. cracking the high boiling fraction in a second downflow reactor of the fluid catalytic cracking unit in the presence of a predetermined amount of catalyst to produce cracked products and spent catalyst;
e. regenerating spent catalyst from both the first and second downflow reactors in a common regeneration zone and recycling the regenerated catalyst back to the first and second downflow reactors; and
f. recovering the first and second cracked product streams.
2. The process of claim 1 , wherein the catalyst-oil ratio in the downflow reactor processing the low boiling fraction is in the range of 10:1 to 40:1.
3. The process of claim 1 , wherein the catalyst-oil ratio in the downflow reactor processing the high boiling fraction is in the range of 20:1 to 60:1.