Cycle oil conversion process

Abstract

The invention relates to a process for converting cycle oils produced in catalytic cracking reactions into olefin and naphtha. More particularly, the invention relates to a process for hydroprocessing a catalytically cracked light cycle oil, and then re-cracking it in an upstream zone of the primary FCC riser reactor.

1 . A method for catalytically cracking a primary feed comprising the continuous steps of: 
 (a) injecting the primary feed into an FCC riser reactor having at least a first reaction zone and a second reaction zone upstream of the first reaction zone, the primary feed being injected into the first reaction zone;    (b) cracking the primary feed in the first reaction zone under catalytic cracking conditions in the presence of a catalytically effective amount of a regenerated zeolite-containing catalytic cracking catalyst in order to form at least spent catalyst and a cracked product;    (c) separating at least a cycle oil from the cracked product and then processing at least a portion of the cycle oil in the presence of a catalytically effective amount of a hydroprocessing catalyst under hydroprocessing conditions in order to form a hydroprocessed cycle oil containing a significant amount of decalins;    (d) injecting the hydroprocessed cycle oil into the second reaction zone; and    (e) cracking the hydroprocessed cycle oil under cycle oil catalytic cracking conditions in the presence of the catalytic cracking catalyst.    
     
     
         2 . The method of    claim 1    wherein the primary feed is at least one of hydrocarbonaceous oils boiling in the range of about 220° C. to about 565° C.; naphtha; gas oil; heavy hydrocarbonaceous oils boiling above 565° C.; heavy and reduced petroleum crude oil; petroleum atmospheric distillation bottoms; petroleum vacuum distillation bottoms; pitch; asphalt; bitumen; tar sand oils; shale oil; and liquid products derived from coal and natural gas.  
     
     
         3 . The method of    claim 1    wherein conditions in the first reaction zone include temperatures from about 450° C. to about 650° C., hydrocarbon partial pressures from about 10 to 40 psia, a primary feed residence time of less than about 20 seconds, and a catalyst to primary feed (wt/wt) ratio from about 3 to 12, where catalyst weight is total weight of the catalyst composite.  
     
     
         4 . The method of    claim 3    wherein steam is concurrently introduced with the primary feed into the first reaction zone.  
     
     
         5 . The method of    claim 1    wherein conditions in the riser reactor's second reaction zone include temperatures from about 550° C. to about 700° C., hydrocarbon partial pressures from about 10 to 40 psia, a cycle oil residence time of less than about 10 seconds, and a catalyst to cycle oil (wt/wt) ratio from about 5 to 100, where catalyst weight is total weight of the catalyst composite.  
     
     
         6 . The method of    claim 5    wherein steam is concurrently introduced with the cycle oil feed into the second reaction zone.  
     
     
         7 . The method of    claim 1    wherein the hydroprocessing is performed in a single hydroprocessing stage at a temperature ranging from about 200° C. to about 550° C., a reaction pressure ranging from about 1000 to about 3000 psig, a space velocity ranging from about 0.1 to 6 V/V/Hr, and a hydrogen charge rate ranging from about 1,000 to about 15,000 standard cubic feet per barrel (SCF/B).  
     
     
         8 . The method of    claim 1    wherein the hydroprocessing is performed in a first hydroprocessing stage and a second hydroprocessing stage, the first hydroprocessing stage being upstream of the second hydroprocessing stage, wherein 
 (a) hydroprocessing conditions in the first stage include single hydroprocessing stage at a temperature ranging from about 200° C. to about 550° C., a reaction pressure ranging from about 1000 to about 3000 psig, a space velocity ranging from about 0.1 to 6 V/V/Hr, and a hydrogen charge rate ranging from about 1,000 to about 15,000 standard cubic feet per barrel (SCF/B), and  
 (b) hydroprocessing conditions in the second stage include a temperature ranging from about 100° C. to about 600° C., a reaction pressure ranging from about 100 to about 3000 psig, a space velocity ranging from about 0.1 to 6 V/V/Hr, and a hydrogen charge rate ranging from about 500 to about 15,000 standard cubic feet per barrel (SCF/B), more preferably from about 500 to about 10,000 SCF/B.  
 
     
     
         9 . The method of    claim 1    further comprising conducting the partially spent catalyst to a stripping zone and removing strippable hydrocarbons in order to form stripped, spent catalyst, and then conducting the stripped spent catalyst to a regeneration zone for regenerating the spent catalyst under FCC catalyst regeneration conditions in order to form the regenerated, zeolite-containing, catalytic cracking catalyst.  
     
     
         10 . The method of    claim 9    further comprising separating propylene from the cracked product and then polymerizing the propylene in order to form polypropylene.