Deep saturation catalysts and process for hydrotreating whole crudes

Abstract

Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into at least light and heavy fractions. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a fluidized catalytic conversion unit, or a residue hydrocracking unit that may utilize an ebullated bed reactor. Products from the upgrading operations may be used as feed to a steam cracker.

We claim: 
     
         1 . A deep saturation catalyst system for converting whole crudes and other heavy hydrocarbon streams to produce olefins and/or aromatics, the catalyst system comprising:
 a supported hydrogenation catalyst, and   a self-supported hydrogenation catalyst.   
     
     
         2 . The catalyst system according to  claim 1 , wherein the catalyst system does not comprise a hydrocracking catalyst. 
     
     
         3 . The catalyst system according to  claim 1 , wherein the self-supported hydrogenation catalyst is ICR 1000. 
     
     
         4 . The catalyst system a according to  claim 1 , wherein the production of chemicals from a whole crude feed is at least 65%. 
     
     
         5 . A process for converting whole crudes and other heavy hydrocarbon streams to produce olefins and/or aromatics, the process comprising:
 separating a whole crude into at least a light boiling fraction, a medium boiling fraction, and a high boiling residue fraction;   separating the high boiling fraction in a solvent deasphalting unit to produce a deasphalted oil fraction and a pitch fraction;   destructively hydrogenating the deasphalted oil fraction and the medium boiling fraction using the catalyst system according to  claim 1  to produce a hydrotreated effluent;   feeding the hydrotreated effluent and the light boiling fraction to a steam cracker to convert hydrocarbons therein into one or more light olefins and a pyrolysis oil.   
     
     
         6 . The process according to  claim 5 , wherein the deasphalted oil fraction and the medium boiling fraction are converted in an ebullated bed or slurry reactor before steam cracking. 
     
     
         7 . The process of  claim 5 , wherein the light boiling fraction has two or more of the following properties:
 a 95% boiling point temperature in the range from about 130° C. to about 200° C.;   a hydrogen content of at least 14 wt %;   a BMCI of less than 5;   an API gravity of greater than 40°;   a sulfur content of less than 1000 ppm;   a nitrogen content of less than 10 ppm;   a viscosity, measured at 40° C., of less than 1 cSt;   less than 1 wt % MCRT; and   less than 1 ppm total metals.   
     
     
         8 . The process of  claim 5 , wherein the medium boiling fraction has two or more of the following properties:
 a 5% boiling point temperature in the range from about 130° C. to about 200° C.;   a 95% boiling point temperature in the range from about 400° C. to about 600° C.;   a hydrogen content in the range from about 12 wt % to about 14 wt %;   a BMCI in the range from about 5 to less than 50;   an API gravity of in the range from about 100 to about 40°;   a sulfur content in the range from about 1000 ppm to about 10000 ppm;   a nitrogen content in the range from about 1 ppm to about 100 ppm;   a viscosity, measured at 40° C., of greater than 1 cSt;   less than 5 wt % MCRT; and   less than 50 ppm total metals.   
     
     
         9 . The process of  claim 5 , wherein the high boiling residue fraction has two or more of the following properties:
 a 5% boiling point temperature in the range from about 400° C. to about 600° C.;   a hydrogen content of less than 12 wt %;   a BMCI of greater than 50;   an API gravity of less than 10°;   a sulfur content of greater than 10000 ppm;   a nitrogen content of greater than 100 ppm;   a viscosity, measured at 100° C., of greater than 100 cSt;   greater than 5 wt % MCRT; and   greater than 50 ppm total metals.   
     
     
         10 . The process of  claim 5 , wherein an overall chemicals production of the feedstock is at least 65 wt %, based on the total amount of olefins produced as compared to a total feedstock feed rate. 
     
     
         11 . The process of  claim 5 , wherein destructively hydrogenating comprises converting hydrocarbons in the deasphalted oil fraction to one or more steam crackable products. 
     
     
         12 . The process of  claim 5 , wherein separating the whole crude comprises:
 feeding the whole crude into a heater, producing a pre-heated hydrocarbon feedstock;   separating the pre-heated hydrocarbon feedstock in a separator into the light boiling fraction and an intermediate fraction;   feeding the intermediate fraction back to the heater, producing a heated intermediate fraction;   feeding a hydrogen stream to a hot hydrogen stripper;   separating the heated intermediate fraction in the hot hydrogen stripper into the medium boiling fraction and a hot hydrogen stripper bottoms fraction; and   cooling the hot hydrogen stripper bottoms fraction via indirect heat exchange against the intermediate fraction producing the high boiling residue fraction.   
     
     
         13 . The process of  claim 7 , wherein the light boiling fraction does not comprise hydrocarbons having a boiling point of greater than 160° C. 
     
     
         14 . The process of  claim 7 , wherein destructively hydrogenation the deasphalted oil fraction and the middle fraction comprises converting hydrocarbons in the deasphalted oil fraction and the middle fraction to primarily steam crackable products.