The present invention relates to a process and system for complete conversion of crude oils by integrating Desalter unit, Atmospheric and vacuum column, high severity FCC process, Naphtha cracking process, residue slurry hydrocracking process, Delayed coking process, Selective mild hydrocracking aromatic production unit, Dehydrogenation units, Aromatic/olefin recovery section, gasifier unit along with syngas to olefins conversion section.

The invention concerns a process for converting a hydrocarbon feed, said process comprising the following steps: a) a step of hydrocracking the feed in the presence of hydrogen; b) a step of separating the effluent obtained from step a); c) a step of precipitating sediments, in which the heavy fraction obtained from the separation step b) is brought into contact with a distillate cut at least 20% by weight of which has a boiling point of 100° C. or more for a period of less than 500 minutes, at a temperature in the range 25° C. to 350° C., and at a pressure of less than 20 MPa; d) a step of physical separation of the sediments from the heavy fraction obtained from step c); e) a step of recovering a heavy fraction having a sediment content, measured using the ISO 10307-2 method, of 0.1% by weight or less.

Methods and apparatus for processing hydrocarbon and other feedstocks that contain lighter volatile component(s) along with heavier volatile or non-volatile component(s) and/or contaminant(s). The principal benefit being that a feedstock can be processed and separated into its distinct volatile components down to elemental and/or molecular levels, including the ability to handle the heaviest tars and bitumen within the system. This effectively provides onsite value add to the feedstock resource (minus the waste streams such as water, sulfur, or sand; which may have value as isolated components in their own right). The system is robust and can include innovative hardware, methods, and/or software. The system can isolate water, chemical, various hydrocarbon, and particle contaminants of arbitrary concentrations and sizes. These factors provide for significant increases in processing efficiencies and capabilities in the fields of refining and environmental recovery. In a variety of operating scenarios, near-zero emissions can be achieved while processing.

Method of producing pyrolysis products from mixed plastics along with an associated system for processing mixed plastics. The method includes conducting pyrolysis of a plastic feedstock to produce plastic pyrolysis oil; feeding the plastic pyrolysis oil to a first fractionator to separate the plastic pyrolysis oil into a distillate fraction including naphtha and diesel and a vacuum gas oil fraction; and feeding the distillate fraction to a three step hydrotreating operation. The three step hydrotreating operation includes feeding the distillate fraction to a first hydrotreating unit to remove di-olefins to produce a first product stream, feeding the first product stream to a second hydrotreating unit to remove mono-olefins to produce a second product stream; and feeding the second product stream to a third hydrotreating unit to remove sulfur and nitrogen by hydrodesulfurization and hydrodenitrogenation to produce a third product stream. Such system may be integrated with a conventional refinery.

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.

Where thermochemical liquefaction of lignocellulosic biomass is conducted using recirculated product oil as solvent, yields can be substantially increased by addition of a short chain alcohol reactant such as ethanol or methanol. A synergistic effect is thereby obtained where liquefaction is improved over using either recycled product oil or alcohol alone. The combination of re-circulated product oil and alcohol reactant permits high conversion at operating pressures considerably lower than typically applied in alcohol solvolysis, typically within the range 30-60 bar. The liquefaction reaction occurs at subcritical pressure where the alcohol acts as a gaseous reactant and not as a solvent.

A nonlimiting example method for producing a diesel boiling range composition comprises: oligomerizing an ethylene stream to a C4+ olefin stream in a first olefin oligomerization unit, wherein the C4+ olefin stream contains no greater than 10 wt% of methane, ethylene, and ethane combined in a first oligomerization; and wherein the ethylene stream contains at least 50 wt% ethylene, at least 2000 wppm ethane, no greater than 1000 wppm of methane, and no greater than 20 wppm each of carbon monoxide and hydrogen; oligomerizing the C4+ olefin stream and a propylene/C4+ olefin stream in a second oligomerization unit to produce an isoolefinic stream; wherein at least a portion of the isoolefinic stream is used to create the diesel boiling range composition.

A desolidification process enables the isolation and extraction of solid additives from an unreacted petroleum residue stream. In a hydrocracking process that mixes a solid additive with a petroleum residue feedstock to convert the petroleum residue to higher-value distillates, the desolidification process enables the recovery of the unreacted petroleum residue for conversion to a saleable product. The desolidification process involves the mixture of one or more solvents with a slurry in which solids are integrated in the petroleum residue to generate a mixture having a decreased density and viscosity as compared to the slurry, which facilitates removal of the solids.

A system for upgrading heavy hydrocarbon feeds, such as crude oil, include a hydrotreating unit, a hydrotreated effluent separation system, a solvent-assisted adsorption system, and a hydrocracking unit. Processes for upgrading heavy hydrocarbon feeds include hydrotreating the hydrocarbon feed to produce a hydrotreated effluent that includes asphaltenes, separating the hydrotreated effluent into a lesser boiling hydrotreated effluent and a greater boiling hydrotreated effluent comprising the asphaltenes, combining the greater boiling hydrotreated effluent with a light paraffin solvent to produce a combined stream, adsorbing the asphaltenes from the combined stream to produce an adsorption effluent, and hydrocracking the lesser boiling hydrotreated effluent and at least a portion of the adsorption effluent to produce a hydrocracked effluent with hydrocarbons boiling less than 180° C. The systems and processes increase the hydrocarbon conversion and yield of hydrocarbons boiling less than 180° C.

A method of converting a liquid hydrocarbon stream to lower boiling point hydrocarbons may include converting the liquid hydrocarbon stream to an aerosolized hydrocarbon particle stream, and subjecting the aerosolized hydrocarbon particle stream to reaction conditions. Reaction conditions may include a temperature from 25° C. to 1,000° C. and a pressure from 1 bar to 15 bar. The method may further include forming the lower boiling point hydrocarbons in the aerosolized hydrocarbon particle stream and separating the lower boiling point hydrocarbons from the aerosolized hydrocarbon particle stream. The lower boiling point hydrocarbons may comprise at least C.sub.2-C.sub.4 olefins.