Process and Apparatus for Integrated Heavy Oil Upgrading

Abstract

A process and apparatus is disclosed for converting heavy hydrocarbon feed into lighter hydrocarbon products. The heavy hydrocarbon feed is slurried with a particulate solid material to form a heavy hydrocarbon slurry and hydrocracked to produce vacuum gas oil (VGO). A light portion of the VGO may be hydrotreated and subjected to fluid catalytic cracking to produce fuels such as gasoline. A heavy portion of the VGO may be recycled to the slurry hydrocracking reactor. FCC slurry oil may be recycled to the slurry for hydrocracking.

1 . A process for converting heavy hydrocarbon feed into lighter hydrocarbon products comprising:
 mixing said heavy hydrocarbon feed with a particulate solid material to form a heavy hydrocarbon slurry;   hydrocracking said heavy hydrocarbon slurry in the presence of hydrogen in a hydrocracking reactor to produce a hydrocracked stream including vacuum gas oil (VGO);   hydrotreating at least a portion of said hydrocracked stream including light VGO in the presence of a hydrotreating catalyst to produce a hydrotreated stream; and   cracking at least a portion of said hydrotreated stream with a hot stream of fluidized catalyst to produce a cracked product stream including gasoline.   
   
   
       2 . The process of  claim 1  further comprising separating said hydrocracked stream to provide a gaseous hydrocracked stream and a liquid hydrocracked stream and hydrotreating said gaseous hydrocracked stream. 
   
   
       3 . The process of  claim 2  further comprising fractionating said liquid hydrocracked stream to provide an overhead stream including light VGO and cracking said overhead stream with a hot stream of fluidized catalyst to produce cracked product including gasoline. 
   
   
       4 . The process of  claim 3  further comprising fractionating said liquid hydrocracked stream to provide a bottoms stream comprising pitch and mixing at least a portion of said pitch with said heavy hydrocarbon feed. 
   
   
       5 . The process of  claim 3  further comprising fractionating said liquid hydrocracked stream to provide a side stream comprising heavy VGO which is mixed with said heavy hydrocarbon feed. 
   
   
       6 . The process of  claim 5  further comprising fractionating said liquid hydrocracked stream to provide an overhead stream and cracking at least a portion of said overhead stream with a hot stream of fluidized catalyst to produce a cracked product stream including gasoline. 
   
   
       7 . The process of  claim 6  further comprising hydrotreating said overhead stream before cracking it. 
   
   
       8 . The process of  claim 1  further comprising separating light gases from said hydrotreated stream to form a degassed hydrotreated stream. 
   
   
       9 . The process of  claim 8  further comprising fractionating said degassed hydrotreated stream to obtain a light VGO stream. 
   
   
       10 . The process of  claim 9  further comprising cracking said light VGO stream with a hot stream of fluidized catalyst to produce a cracked product including gasoline. 
   
   
       11 . The process of  claim 1  further comprising fractionating said cracked product stream to produce a bottoms stream comprising main column bottoms which is mixed with said heavy hydrocarbon feed. 
   
   
       12 . The process of  claim 11  further comprising mixing said slurry oil containing FCC catalyst with said heavy hydrocarbon feed without removing said FCC catalyst. 
   
   
       13 . The process of  claim 1  wherein the particulate solid material comprises iron. 
   
   
       14 . A process for converting heavy hydrocarbon feed into lighter hydrocarbon products comprising:
 mixing said heavy hydrocarbon feed with a particulate solid material to form a heavy hydrocarbon slurry;   hydrocracking said heavy hydrocarbon slurry in the presence of hydrogen in a hydrocracking reactor to produce a hydrocracked stream including vacuum gas oil (VGO);   hydrotreating a gaseous portion of said hydrocracked stream including light VGO in the presence of a hydrotreating catalyst to produce a hydrotreated stream;   fractionating a liquid portion of said hydrocracked stream to provide a fractionated stream including light VGO; and   cracking at least a portion of said hydrotreated stream and said fractionated stream with a hot stream of fluidized catalyst to produce a cracked product stream including gasoline.   
   
   
       15 . The process of  claim 14  further comprising fractionating a liquid portion of said hydrocracked stream to provide a side stream comprising heavy VGO and a bottoms stream comprising pitch which are mixed with said heavy hydrocarbon feed. 
   
   
       16 . The process of  claim 14  further comprising fractionating said cracked product stream to produce a bottoms stream comprising main column bottoms which is mixed with said heavy hydrocarbon feed. 
   
   
       17 . A process for converting heavy hydrocarbon feed into lighter hydrocarbon products comprising:
 mixing said heavy hydrocarbon feed with a particulate solid material to form a heavy hydrocarbon slurry;   hydrocracking said heavy hydrocarbon slurry in the presence of hydrogen in a hydrocracking reactor to produce a hydrocracked stream including vacuum gas oil (VGO);   hydrotreating a portion of said hydrocracked stream including light VGO in the presence of a hydrotreating catalyst to produce a hydrotreated stream;   cracking at least a portion of said hydrotreated stream and said fractionated stream with a hot stream of fluidized catalyst to produce a cracked product stream including gasoline; and   fractionating said cracked product stream to produce a bottoms stream comprising main column bottoms which is mixed with said heavy hydrocarbon feed.   
   
   
       18 . The process of  claim 17  further comprising fractionating a liquid portion of said hydrocracked stream to provide a side stream comprising heavy VGO and a bottoms stream comprising pitch which are mixed with said heavy hydrocarbon feed and wherein a gaseous portion of said hydrocracked stream including light VGO is hydrotreated in the presence of said hydrotreating catalyst to produce said hydrotreated stream.