Systems and methods for steam and catalytic cracking of a hydrocarbon inlet stream comprising hydrocarbons. Systems and methods can include a catalyst feed stream, where the catalyst feed stream comprises a fluid and a heterogeneous catalyst, the heterogeneous catalyst operable to catalyze cracking of the hydrocarbons on surfaces of the heterogeneous catalyst a steam feed stream, where the steam feed stream is operable to effect steam cracking of the hydrocarbons, and where the steam feed stream decreases coking of the heterogeneous catalyst; and a downflow reactor, where the downflow reactor is operable to accept and mix the hydrocarbon inlet stream, the catalyst feed stream, and the steam feed stream, where the downflow reactor is operable to produce light olefins by steam cracking and catalytic cracking, and where the downflow reactor is operable to allow the heterogeneous catalyst to flow downwardly by gravity.

A hydroprocessing system having a processing vessel that discharges a high temperature effluent that must be cooled prior to collection in a reflux drum. One or more gas assisted spray nozzle are provided that utilize light atomizing gas having a density of 8-15 times less than air, such as hydrogen, which preferably is the processing or recycle gas of the system. The spray nozzles are designed for the efficient atomization and direction of cooling water into a micron sized droplet distribution utilizing the light atomizing gas for affecting higher mass and heat transfer from the effluent. The spray nozzles each include a unique atomizing gas and cooling liquid passageway systems, a downstream impingement post, and a plurality of discharge orifices which sequentially breakdown the liquid into micron sized droplets as low as 500 microns and less.

A hydroprocessing system having a processing vessel that discharges a high temperature effluent that must be cooled prior to collection in a reflux drum. One or more gas assisted spray nozzle are provided that utilize light atomizing gas having a density of 8-15 times less than air, such as hydrogen, which preferably is the processing or recycle gas of the system. The spray nozzles are designed for the efficient atomization and direction of cooling water into a micron sized droplet distribution utilizing the light atomizing gas for affecting higher mass and heat transfer from the effluent. The spray nozzles each include a unique atomizing gas and cooling liquid passageway systems, a downstream impingement post, and a plurality of discharge orifices which sequentially breakdown the liquid into micron sized droplets as low as 500 microns and less.

In accordance with one or more embodiments herein, an integrated process for upgrading a hydrocarbon oil feed stream utilizing a delayed coker, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; delayed coking the heavy residual hydrocarbons; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a light C.sub.5+ hydrocarbon stream and a heavy C.sub.5+ hydrocarbon stream; steam enhanced catalytically cracking the light C.sub.5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C.sub.5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

In accordance with one or more embodiments herein, an integrated process for upgrading a hydrocarbon oil feed stream utilizing a delayed coker, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; delayed coking the heavy residual hydrocarbons; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a light C.sub.5+ hydrocarbon stream and a heavy C.sub.5+ hydrocarbon stream; steam enhanced catalytically cracking the light C.sub.5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C.sub.5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

An integrated process for upgrading a hydrocarbon oil feed stream includes solvent deasphalting the hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons, delayed coking the heavy residual hydrocarbons to form petroleum coke and a delayed coker product stream; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a C.sub.3-C.sub.4 hydrocarbon stream, a light C.sub.5+ hydrocarbon stream, and a heavy c.sub.5+ hydrocarbon stream; dehydrogenating the C.sub.3-C.sub.4 hydrocarbon stream to form propylene and butylene; steam enhanced catalytically cracking the light C.sub.5+ hydrocarbon stream to form a light steam enhanced catalytically cracked product stream including olefins, benzene, toluene, xylene, naphtha, or combinations thereof; and steam enhanced catalytically cracking the heavy C.sub.5+ hydrocarbon stream to form a heavy steam enhanced catalytically cracked product including olefins, benzene, toluene, xylene, naphtha, or combinations thereof.

An integrated process for upgrading a hydrocarbon oil feed stream includes solvent deasphalting the hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons, delayed coking the heavy residual hydrocarbons to form petroleum coke and a delayed coker product stream; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a C.sub.3-C.sub.4 hydrocarbon stream, a light C.sub.5+ hydrocarbon stream, and a heavy c.sub.5+ hydrocarbon stream; dehydrogenating the C.sub.3-C.sub.4 hydrocarbon stream to form propylene and butylene; steam enhanced catalytically cracking the light C.sub.5+ hydrocarbon stream to form a light steam enhanced catalytically cracked product stream including olefins, benzene, toluene, xylene, naphtha, or combinations thereof; and steam enhanced catalytically cracking the heavy C.sub.5+ hydrocarbon stream to form a heavy steam enhanced catalytically cracked product including olefins, benzene, toluene, xylene, naphtha, or combinations thereof.

In accordance with one or more embodiments herein, an integrated process for upgrading a hydrocarbon oil feed stream utilizing a gasification unit, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; processing the heavy residual hydrocarbons in a gasification unit to form syngas and gasification residue; hydrotreating the deasphalted oil stream to form a light C.sub.5+ hydrocarbon stream and a heavy C.sub.5+ hydrocarbon stream; steam enhanced catalytically cracking the light C.sub.5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C.sub.5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

In accordance with one or more embodiments herein, an integrated process for upgrading a hydrocarbon oil feed stream utilizing a gasification unit, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; processing the heavy residual hydrocarbons in a gasification unit to form syngas and gasification residue; hydrotreating the deasphalted oil stream to form a light C.sub.5+ hydrocarbon stream and a heavy C.sub.5+ hydrocarbon stream; steam enhanced catalytically cracking the light C.sub.5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C.sub.5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

An integrated process for upgrading a hydrocarbon oil feed stream includes solvent deasphalting the hydrocarbon oil stream; processing the heavy residual hydrocarbons in a gasification unit to form syngas and gasification residue; hydrotreating the deasphalted oil stream to form a C.sub.3-C.sub.4 hydrocarbon stream, a light C.sub.5+ hydrocarbon stream, and a heavy C.sub.5+ hydrocarbon stream; dehydrogenating the C.sub.3-C.sub.4 hydrocarbon stream to form propylene and butylene; steam enhanced catalytically cracking the light C.sub.5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C.sub.5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.