Multi-Stage Hydroprocessing for the Production of High Octane Naphtha

Abstract

An integrated process is provided for producing high octane naphtha. Hydrocracked naphtha from a hydrocracking reaction zone is contacted with a reforming catalyst that includes a silicate having a silica to alumina molar ratio of at least 200, and a crystallite size of less than 10 microns. Products from the reforming include a reformed naphtha and a hydrogen-rich stream, which is passed to the hydrocracking reaction zone.

1 . An integrated process for producing high octane naphtha, comprising
 a. isolating a hydrocracked naphtha from a hydrocracking reaction zone effluent;   b. providing at least a portion of the hydrocracked naphtha to a reforming reaction zone containing a reforming catalyst that comprises a silicate having a silica to alumina molar ratio of at least 200, and a crystallite size of less than 10 microns;   c. contacting the at least a portion of the hydrocracked naphtha with the reforming catalyst at reforming reaction conditions and producing a hydrogen-rich stream and a reformed naphtha; and   d. passing the hydrogen-rich stream to the hydrocracking reaction zone.   
     
     
         2 . The process of  claim 1 , wherein step (a) comprises contacting a hydrocarbonaceous feedstock that boils in the range of from 550° F. to 1100° F. (288-593° C.) in a hydrocracking reaction zone to form the effluent. 
     
     
         3 . The process of  claim 1 , wherein step (a) comprises isolating the hydrocracked naphtha that comprises at least 70 wt % C 4  to C 10  hydrocarbons. 
     
     
         4 . The process of  claim 1 , wherein step (a) comprises isolating the hydrocracked naphtha having an octane of less than 90. 
     
     
         5 . The process of  claim 2 , wherein step (a) comprises fractionating the hydrocracking reaction zone effluent and isolating at least the hydrocracked naphtha and a bottoms stream. 
     
     
         6 . The process of  claim 5 , further comprising recycling at least a portion of the bottoms stream to the hydrocracking reaction zone. 
     
     
         7 . The process of  claim 1 , wherein step (b) comprises providing at least a portion of the hydrocracked naphtha to a reforming reaction zone containing a reforming catalyst that comprises a silicate having a silica to alumina molar ratio of at least 500 and a crystallite size of less than 10 microns; 
     
     
         8 . The process of  claim 1 , wherein step (b) comprises providing at least a portion of the hydrocracked naphtha to a reforming reaction zone containing a reforming catalyst that comprises a silicate having a silica to alumina molar ratio of at least 200, a crystallite size of less than 10 microns, and an alkali content of less than 5000 ppm. 
     
     
         9 . The process of  claim 1 , wherein step (b) comprises providing at least a portion of the hydrocracked naphtha to a reforming reaction zone containing a reforming catalyst that comprises a silicate having a silica to alumina molar ratio of at least 200 and a crystallite size of less than 10 microns, the catalyst further comprising one or more of iridium, palladium, platinum or a combination thereof. 
     
     
         10 . The process of  claim 1 , wherein step (c) comprises contacting the at least a portion of the hydrocracked naphtha with the reforming catalyst at reforming conditions, including a pressure in the range of between 0 psig and 250 psig, a temperature in the range of between 600° and 1100° F. and a liquid feed rate in the range of between 0.1 and 20 hr −1 . 
     
     
         11 . The process of  claim 1 , wherein step (c) comprises producing the reformed naphtha that comprises at least 70 wt % C 5  to C 9  hydrocarbons. 
     
     
         12 . The process of  claim 4 , wherein step (c) comprises producing the reformed naphtha having an octane that is greater than the octane of the hydrocracked naphtha. 
     
     
         13 . The process of  claim 4 , wherein step (c) comprises producing the reformed naphtha having an octane of greater than 90. 
     
     
         14 . The process of  claim 1 , further comprising combining at least a portion of the hydrocracked naphtha with at least a portion of the reformed naphtha. 
     
     
         15 . An integrated process for producing high octane naphtha, comprising
 a. isolating a hydrocracked naphtha from a hydrocracking reaction zone effluent;   b. providing a first portion of the hydrocracked naphtha to a reforming reaction zone containing a reforming catalyst that comprises a silicate having a silica to alumina molar ratio of at least 200, and a crystallite size of less than 10 microns;   c. contacting the first portion of the hydrocracked naphtha with the reforming catalyst at reforming reaction conditions and producing a hydrogen-rich stream and a reformed naphtha;   d. passing the hydrogen-rich stream to the hydrocracking reaction zone; and   e. combining the reformed naphtha with a second portion of the hydrocracked naphtha to form a combined naphtha having an octane of greater than 90.   
     
     
         16 . A system for producing high octane naphtha, comprising:
 a. a hydrocracking reaction zone for producing a hydrocracked naphtha from a hydrocarbonaceous feedstock;   b. a reforming reaction zone for reforming the hydrocracked naphtha and for producing a reformed naphtha and a reformer hydrogen; and   c. a means for supplying the reformer hydrogen to the hydrocracking reaction zone.   
     
     
         17 . The system of  claim 16 , further comprising forming a combined naphtha by blending at least a portion of the hydrocracked naphtha with at least a portion of the reformed naphtha. 
     
     
         18 . The system of  claim 16 , wherein the reformer reaction zone contains a reforming catalyst that comprises a silicate having a silica to alumina molar ratio of at least 200, and a crystallite size of less than 10 microns. 
     
     
         19 . The system of  claim 16 , wherein the hydrocracked naphtha comprises at least 70 wt % C 4  to C 10  hydrocarbons and the reformed naphtha comprises at least 70 wt % C 5  to C 9  hydrocarbons. 
     
     
         20 . The system of  claim 16 , wherein the hydrocracked naphtha has an octane of less than 90 and the reformed naphtha has an octane of greater than 90. 
     
     
         21 . The system of  claim 16 , wherein the combined naphtha has an octane of greater than 90.