Processes for treating highly viscous hydrocarbons, such as bitumen from oil sands or petroleum residues, with hydrogen-donor solvents are described. The hydrogen-donor solvent is prepared. A mixture of the hydrocarbon and the hydrogen-donor solvent is heated, and the product is cooled to produce a low viscosity and mildly upgraded hydrocarbon. The hydrogen-donor solvent can be modified to improve its solvent usefulness.

Relatively low value disulfide oil (DSO) compounds produced as by-products of the mercaptan oxidation (MEROX) processing of refinery hydrocarbon streams, and oxidized disulfide oils (ODSO), are economically converted to value-added BTX by introducing the DSO and/or ODSO compounds as the feed to a fluidized catalytic cracking (FCC) unit and recovering the liquid products. The liquid FCC products are introduced as the feedstream to a selective naphtha hydrogenation and hydrotreating process for desulfurization and are then further separated in an aromatics extraction process for the recovery of BTX.

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.

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.

A process for purification a hydrocarbon stream including: (a) Providing a hydrocarbon stream having a diene value of at least 1.0, a bromine number of at least 5 g and containing at least 10 wt % of pyrolysis plastic oil; b) contacting the effluent obtained in step a) with a silica gel, clays, alkaline or alkaline earth metal oxide, iron oxide, ion exchange resins, active carbon, active aluminium oxide, molecular sieves, alkaline oxide and/or porous supports, and/or silica gel, or any mixture thereof; c) performing a first hydrotreating step; d) contacting the effluent obtained in step c) with silica gel, clays, alkaline or alkaline earth metal oxide, iron oxide, ion exchange resins, active carbon, active aluminium oxide, molecular sieves, alkaline oxide and/or porous supports and silica gel, or any mixture thereof; e) performing a second hydrotreating step; and f) recovering a purified hydrocarbon stream.

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.

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.

A method for operating an acetylene hydrogenation unit in an integrated steam cracking-fluidized catalytic dehydrogenation (FCDh) system may include separating a cracked gas from a steam cracking system and an FCDh effluent from an FCDh system into a hydrogenation feed and an acetylene-depleted stream, the hydrogenation feed comprising at least hydrogen, CO, and acetylene. During normal operating conditions, at least 20% of the CO in the hydrogenation feed is from the cracked gas. The method may include contacting the hydrogenation feed with an acetylene hydrogenation catalyst to hydrogenate at least a portion of the acetylene in the hydrogenation feed to produce a hydrogenated effluent. The steam cracking is operated under conditions that increase CO production such that a concentration of CO in the cracked gas is great enough that when a flowrate of the FCDh effluent is zero, a CO concentration in the hydrogenation feed is at least 100 ppmv.

A process for the purification of a hydrocarbon stream including: (a) Providing a hydrocarbon stream having a diene value of at least 1.0 and a bromine number of at least 5 gBr2/100 g and containing pyrolysis plastic oil; (b) Optionally contact the hydrocarbon stream obtained in step (a) with a silica gel, clays, alkaline or alkaline earth metal oxide, iron oxide, ion exchange resins, active carbon, active aluminum oxide, molecular sieves, alkaline oxide and/or porous supports and silica gel, or any mixture thereof; (c) Heating the stream obtained in step a) or b) followed by a mixing of the heated stream with a second diluent heated at a temperature of at least 300° C. preferably at least 330° C.; (d) performing an hydroprocessing step at a temperature of at least 250° C. in the presence of H2; and (e) recovering a purified hydrocarbon stream.

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.