System and process for steam cracking and PFO treatment integrating hydrodealkylation and naphtha reforming

1. An integrated process comprising:

providing a treated crude oil as a steam cracking feed by

hydroprocessing a crude oil stream as a hydroprocessed crude oil steam cracking feed,

hydroprocessing a crude oil stream as a hydroprocessed crude oil, and removing vacuum residue components from said hydroprocessed crude oil, as a bottomless crude oil steam cracking feed,

hydroprocessing a crude oil stream as a hydroprocessed crude oil, and removing components in and below a naphtha or light naphtha range, as a topped crude oil steam cracking feed, or

subjecting a hydroprocessed crude oil, a bottomless crude oil or a topped crude oil to solvent deasphalting to recover deasphalted oil as a deasphalted oil steam cracking feed;

steam cracking said steam cracking feed in a steam cracking zone to produce olefins, pyrolysis gasoline and refractory PFO, wherein said refractory PFO comprises at least 40 wt % of polyaromatics having three or more aromatic rings including triaromatics, naphtheno-triaromatics, tetraaromatics, penta-aromatics and heavier poly-aromatics including asphaltenes and coke;

optionally separating the refractory PFO into at least a first stream containing C9+ aromatics compounds with one benzene ring and C10+ aromatic compounds, and a second stream containing C20+ polyaromatic compounds;

reacting all or a portion of the refractory PFO, or all or a portion of the first stream containing C9+ aromatics compounds with one benzene ring and C10+ aromatic compounds, using conditions, including hydrogen, effective for conversion of polyaromatics compounds contained in the refractory PFO into aromatic compounds with one benzene ring, selective ring opening, and dealkylation, to produce reaction effluent including LPG and a hydrodealkylated BTX+stream, wherein reacting all or a portion of the refractory PFO, or all or a portion of the first stream containing C9+ aromatics compounds with one benzene ring and C10+ aromatic compounds, is in the presence of an effective quantity of a first functional catalyst and a second functional catalyst, or is in the presence of an effective quantity of a multi-functional catalyst,

wherein the first functional catalyst and the second functional catalyst are provided in multiple beds of the different functional catalysts in a reaction vessel, in multiple reaction vessels in series having the different functional catalysts, or as a mixture of the different functional catalysts in a reaction vessel, wherein the first functional catalyst is effective to promote conversion of polyaromatics including naphthalene, methylnaphthalene, anthracene and naphtheno-diaromatics by selective hydrogenation into aromatic compounds with one benzene ring, and comprises one or more first active components selected from the group consisting of Mo, Co, Ir, Pd, Pt, Ni, W, Sn and Ga, and optionally a second active component P, deposited or otherwise incorporated on a support comprising alumina and/or amorphous silica alumina, and wherein the second functional catalyst is effective to promote selective ring opening and hydrodealkylation, and comprises one or more active components selected from the group consisting of Ni, W and Mo, deposited or otherwise incorporated on a support comprising acidic alumina, silica alumina and/or zeolite, or

wherein the multi-functional catalyst is provided in a reaction vessel, wherein the multi-functional catalyst is effective to promote conversion of polyaromatics including naphthalene, methylnaphthalene, anthracene and naphtheno-diaromatics by selective hydrogenation into aromatic compounds with one benzene ring as a first function, and selective ring opening and hydrodealkylation as a second function, wherein the multi-functional catalyst comprises one or more first functional active components selected from the group consisting of Mo, Co, Ir, Pd, Pt, Ni, W, Sn and Ga, optionally in combination with P, and one or more second functional components selected from the group consisting of Ni, W and Mo, wherein the first functional active components and the second functional active components are deposited or otherwise incorporated on a support comprising acidic alumina, silica alumina and/or zeolite;

separating LPG from the reaction effluent;

subjecting a naphtha feed to catalytic reforming to produce a reformate stream; and

separating at least a portion of the reformate stream and at least a portion of the hydrodealkylated BTX+ stream into BTX compounds.

2. The process as in claim 1 , wherein all or a portion of the C20+ polyaromatic compounds are separated as the second stream prior to reacting all or a portion of the first stream to produce the hydrodealkylated BTX+ stream, and wherein reaction conditions comprise a reaction temperature (° C.) in the range of about 300-500, a reaction pressure (hydrogen partial pressure, kg/cm 2 ) in the range of about 3-25, a hydrogen feed rate (standard liters per liter of hydrocarbon feed, SLt/Lt) in the range of about 1-25, and a LHSV in the range of about 0.1-8.

3. The process as in claim 1 , wherein the refractory PFO stream or the second stream contains C20+ polyaromatic compounds, and wherein:

reaction conditions to produce a hydrodealkylated BTX+ stream comprise a reaction temperature (° C.) in the range of about 300-550, a reaction pressure (hydrogen partial pressure, kg/cm 2 ) in the range of about 3-30, a hydrogen feed rate (standard liters per liter of hydrocarbon feed, SLt/Lt) in the range of about 1-30, and a LHSV in the range of about 0.1-10.

4. The process as in claim 1 , wherein the separated LPG stream is treated and passed to the steam cracking zone.

5. The process as in claim 1 , wherein separating at least a portion of the hydrodealkylated BTX+ stream into BTX compounds further comprises separating C9 aromatic compounds, and wherein the process further comprises transalkylating the separated C9 aromatic compounds to produce a transalkylated effluent containing additional BTX compounds and light gases, wherein light gases from transalkylating are treated and one or more LPG streams are recovered, and wherein the one or more LPG streams are passed to the steam cracking zone as additional steam cracking feed.

6. The process as in claim 1 , wherein separating at least a portion of the hydrodealkylated BTX+ stream into BTX compounds further comprises separating C9 aromatic compounds, and wherein the process further comprises transalkylating the separated C9 aromatic compounds to produce a transalkylated effluent containing additional BTX compounds, further comprising separating naphtha-range hydrocarbon compounds from the transalkylated effluent prior to separation into BTX compounds, and passing all or a portion of said naphtha-range hydrocarbon compounds to the steam cracking zone as additional steam cracking feed, or wherein all or a portion of said naphtha-range hydrocarbon compounds comprise at least a portion of the naphtha feed to catalytic reforming.

7. The process as in claim 1 , wherein separating at least a portion of the hydrodealkylated BTX+ stream into BTX compounds further comprises separating C9 aromatic compounds, and wherein the process further comprises transalkylating the separated C9 aromatic compounds to produce a transalkylated effluent containing additional BTX compounds, further comprising recovering a raffinate stream comprising non-aromatic compounds from the transalkylated effluent, and passing all or a portion of said raffinate stream to the steam cracking zone as additional steam cracking feed, wherein recovering a raffinate stream is by aromatics extraction to separate the hydrodealkylated BTX+ stream into the raffinate stream and an extract stream comprising aromatic compounds, and wherein the extract stream is separated into the BTX compounds.

8. The process as in claim 1 , wherein separating the hydrodealkylated BTX+ stream into BTX compounds further comprises separating C10+ compounds from the hydrodealkylated BTX+ stream, and wherein at least a portion of the separated C10+ compounds are recycled to the step of reacting with reacting all or a portion of the refractory PFO, or all or a portion of the first stream containing C9+ aromatics compounds with one benzene ring and C10+ aromatic compounds.

9. The process as in claim 1 , wherein separating the hydrodealkylated BTX+ stream into BTX compounds further comprises separating C10+ compounds from the hydrodealkylated BTX+ stream, and wherein at least a portion of the separated C10+ compounds are subjected to hydroprocessing with the crude oil stream.

10. The process as in claim 1 , further comprising separating naphtha-range hydrocarbon compounds from the hydrodealkylated BTX+ stream prior to separation into BTX compounds, and passing all or a portion of said naphtha-range hydrocarbon compounds to the steam cracking zone as additional steam cracking feed.

11. The process as in claim 1 , further comprising separating naphtha-range hydrocarbon compounds from the hydrodealkylated BTX+ stream prior to separation into BTX compounds, wherein all or a portion of said naphtha-range hydrocarbon compounds comprise at least a portion of the naphtha feed to catalytic reforming.

12. The process as in claim 1 , further comprising separating at least a portion of the hydrodealkylated BTX+ stream into BTX compounds includes recovering a raffinate stream comprising non-aromatic compounds, and passing all or a portion of said raffinate stream to the steam cracking zone as additional steam cracking feed.

13. The process as in claim 12 , wherein recovering a raffinate stream is by aromatics extraction to separate the hydrodealkylated BTX+ stream into the raffinate stream and an extract stream comprising aromatic compounds, and wherein the extract stream is separated into the BTX compounds.

14. The process as in claim 1 , further comprising separating at least a portion of the reformate stream into BTX compounds includes recovering a raffinate stream comprising non-aromatic compounds, and passing all or a portion of said raffinate stream to the steam cracking zone as additional steam cracking feed.

15. The process as in claim 14 , wherein recovering a raffinate stream is by aromatics extraction to separate the reformate stream into the raffinate stream and an extract stream comprising aromatic compounds, and wherein the extract stream is separated into the BTX compounds.

16. The process as in claim 1 ,

wherein reacting all or a portion of the refractory PFO, or all or a portion of the first stream containing C9+ aromatics compounds with one benzene ring and C10+ aromatic compounds, is in the presence of an effective quantity of a first functional catalyst and a second functional catalyst; and

wherein the first functional catalyst comprises one or more first active components selected from the group consisting of Mo, Co, Pd, Ni and Sn, and optionally a second active component P, deposited or otherwise incorporated on a support comprising alumina and/or amorphous silica alumina, and wherein the second functional catalyst comprises one or more active components selected from the group consisting of Ni, W and Mo, deposited or otherwise incorporated on a support comprising zeolite.

17. The process as in claim 1 ,

wherein reacting all or a portion of the refractory PFO, or all or a portion of the first stream containing C9+ aromatics compounds with one benzene ring and C10+ aromatic compounds, is in the presence of an effective quantity of a multi-functional catalyst; and

wherein the multi-functional catalyst comprises one or more first functional active components selected from the group consisting of Mo, Co, Pd, Ni and Sn, optionally in combination with P, and one or more second functional components selected from the group consisting of Ni, W and Mo, wherein the first functional active components and the second functional active components are deposited or otherwise incorporated on a support comprising acidic alumina, silica alumina and/or zeolite.

18. The process as in claim 1 , wherein providing the treated crude oil is by hydroprocessing a crude oil stream as a hydroprocessed crude oil steam cracking feed.

19. The process as in claim 1 , wherein providing the treated crude oil is by hydroprocessing a crude oil stream as a hydroprocessed crude oil, and removing vacuum residue components from said hydroprocessed crude oil, as a bottomless crude oil steam cracking feed.

20. The process as in claim 1 , wherein providing the treated crude oil is by hydroprocessing a crude oil stream as a hydroprocessed crude oil, and removing components in and below a naphtha or light naphtha range, as a topped crude oil steam cracking feed.

21. The process as in claim 1 , wherein providing the steam cracking feed is by

hydroprocessing a crude oil stream as a hydroprocessed crude oil steam cracking feed,

hydroprocessing a crude oil stream as a hydroprocessed crude oil, and removing vacuum residue components from said hydroprocessed crude oil, as a bottomless crude oil steam cracking feed, or

hydroprocessing a crude oil stream as a hydroprocessed crude oil, and removing components in and below a naphtha or light naphtha range, as a topped crude oil steam cracking feed; and

subjecting the hydroprocessed crude oil, the bottomless crude oil or the topped crude oil to solvent deasphalting to recover deasphalted oil as a deasphalted oil steam cracking feed.