Process scheme configurations are disclosed that enable conversion of crude oil feeds with several processing units in an integrated manner into petrochemicals. The designs utilize minimum capital expenditures to prepare suitable feedstocks for the steam cracker complex. The integrated process for converting crude oil to petrochemical products including olefins and aromatics, and fuel products, includes mixed feed steam cracking and gas oil steam cracking. Feeds to the mixed feed steam cracker include one or more naphtha fractions from hydroprocessing zones within the battery limits, including vacuum residue hydrocracking, within the battery limits, recycle streams from the C3 and C4 olefins recovery steps, and raffinate from a pyrolysis gasoline aromatics extraction zone within the battery limits. Feed to the gas oil steam cracker in certain embodiments includes gas oil range intermediates from the vacuum residue hydrocracking zone. In addition, a base oil production center is integrated to provide base oils product used for production of synthetic lubes or corresponding lube oil feedstocks.

Process scheme configurations are disclosed that enable conversion of crude oil feeds with several processing units in an integrated manner into petrochemicals. The designs utilize minimum capital expenditures to prepare suitable feedstocks for the steam cracker complex. The integrated process for converting crude oil to petrochemical products including olefins and aromatics, and fuel products, includes mixed feed steam cracking and gas oil steam cracking. Feeds to the mixed feed steam cracker include one or more naphtha fractions from hydroprocessing zones within the battery limits, including vacuum residue hydrocracking, within the battery limits, recycle streams from the C3 and C4 olefins recovery steps, and raffinate from a pyrolysis gasoline aromatics extraction zone within the battery limits. Feeds to the gas oil steam cracker include gas oil range intermediates from the vacuum gas oil hydroprocessing zone and the vacuum residue hydrocracking zone.

A method for upgrading a petroleum feedstock using a supercritical water petroleum upgrading system includes introducing the petroleum feedstock, water and an auxiliary feedstock. The method includes operating the system to combine the petroleum feedstock and the water to form a mixed petroleum feedstock and introducing separately and simultaneously into a lower portion of an upflowing supercritical water reactor. The auxiliary feedstock is introduced such that a portion of a fluid contained within the upflowing reactor located proximate to the bottom does not lack fluid momentum. An embodiment of the method includes operating the supercritical water petroleum upgrading system such that the upflowing reactor product fluid is introduced into an upper portion of a downflowing supercritical water reactor. The supercritical water petroleum upgrading system includes the upflowing supercritical water reactor and optionally a downflowing supercritical water reactor.

A method for upgrading a petroleum feedstock using a supercritical water petroleum upgrading system includes introducing the petroleum feedstock, water and an auxiliary feedstock. The method includes operating the system to combine the petroleum feedstock and the water to form a mixed petroleum feedstock and introducing separately and simultaneously into a lower portion of an upflowing supercritical water reactor. The auxiliary feedstock is introduced such that a portion of a fluid contained within the upflowing reactor located proximate to the bottom does not lack fluid momentum. An embodiment of the method includes operating the supercritical water petroleum upgrading system such that the upflowing reactor product fluid is introduced into an upper portion of a downflowing supercritical water reactor. The supercritical water petroleum upgrading system includes the upflowing supercritical water reactor and optionally a downflowing supercritical water reactor.

Process scheme configurations are disclosed that enable conversion of crude oil feeds with several processing units in an integrated manner into petrochemicals. The designs utilize minimum capital expenditures to prepare suitable feedstocks for the steam cracker complex. The integrated process for converting crude oil to petrochemical products including olefins and aromatics, and fuel products, includes mixed feed steam cracking and gas oil steam cracking. Feeds to the mixed feed steam cracker include light products and naphtha from hydroprocessing zones within the battery limits, recycle streams from the C3 and C4 olefins recovery steps, and raffinate from a pyrolysis gasoline aromatics extraction zone within the battery limits. Feeds to the gas oil steam cracker include gas oil range intermediates from the vacuum gas oil hydroprocessing zone. Furthermore, vacuum residue is processed in a delayed coker unit to produce coker naphtha, which is hydrotreated and passed as additional feed to aromatics extraction zone and/or the mixed feed steam cracker, and coker gas oil range intermediates as additional feed to the gas oil hydroprocessing zone.

Process scheme configurations are disclosed that enable conversion of crude oil feeds with several processing units in an integrated manner into petrochemicals. The designs utilize minimum capital expenditures to prepare suitable feedstocks for the steam cracker complex. The integrated process for converting crude oil to petrochemical products including olefins and aromatics, and fuel products, includes mixed feed steam cracking and gas oil steam cracking. Feeds to the mixed feed steam cracker include light products and naphtha from hydroprocessing zones within the battery limits, recycle streams from the C3 and C4 olefins recovery steps, and raffinate from a pyrolysis gasoline aromatics extraction zone within the battery limits. Feeds to the gas oil steam cracker include unconverted oil intermediates from vacuum gas oil hydrotreating.

Process scheme configurations are disclosed that enable conversion of crude oil feeds with several processing units in an integrated manner into petrochemicals. The designs utilize minimum capital expenditures to prepare suitable feedstocks for the steam cracker complex. The integrated process for converting crude oil to petrochemical products including olefins and aromatics, and fuel products, includes mixed feed steam cracking and conversion of naphtha to chemical rich reformate. Feeds to the mixed feed steam cracker include light products from hydroprocessing zones within the battery limits, recycle streams from the C3 and C4 olefins recovery steps, and raffinate from a pyrolysis gasoline aromatics extraction zone within the battery limits. Chemical reformate from straight run naphtha streams is used as an additional feed to the aromatics extraction zone and or the mixed feed steam cracker. Feeds to the gas oil steam cracker include hydrotreated gas oil range intermediates from the vacuum gas oil hydroprocessing zone.

Systems and processes for the treatment of a naphtha range hydrocarbon feedstock comprising sulfur-containing compounds, nitrogen-containing compounds, olefins, diolefins, and aromatics. The systems and processes are configured to treat the naphtha range hydrocarbon feedstock to convert the sulfur-containing compounds, nitrogen-containing compounds, and olefins, diolefins while less than 2 wt % aromatics are hydrogenated, producing an olefin lean overheads fraction comprising less than 0.2 wt % olefins and less than 100 mg/kg sulfur and an aromatics rich fraction comprising less than 50 ppmw olefins, less than 0.5 ppmw sulfur and less than 0.5 ppmw nitrogen.

Systems and processes for the treatment of a naphtha range hydrocarbon feedstock comprising sulfur-containing compounds, nitrogen-containing compounds, olefins, diolefins, and aromatics. The systems and processes are configured to treat the naphtha range hydrocarbon feedstock to convert the sulfur-containing compounds, nitrogen-containing compounds, and olefins, diolefins while less than 2 wt % aromatics are hydrogenated, producing an olefin lean overheads fraction comprising less than 0.2 wt % olefins and less than 100 mg/kg sulfur and an aromatics rich fraction comprising less than 50 ppmw olefins, less than 0.5 ppmw sulfur and less than 0.5 ppmw nitrogen.

A supercritical water separation process and system is disclosed for the removal of metals, minerals, particulate, asphaltenes, and resins from a contaminated organic material. The present invention takes advantage of the physical and chemical properties of supercritical water to effect the desired separation of contaminants from organic materials and permit scale-up. At a temperature and pressure above the critical point of water (374 C., 22.1 MPa), nonpolar organic compounds become miscible in supercritical water (SCW) and polar compounds and asphaltenes become immiscible. The process and system disclosed continuously separates immiscible contaminants and solids from the supercritical water and clean oil product solution. The present invention creates a density gradient that enables over 95% recovery of clean oil and over 99% reduction of contaminants such as asphaltenes and particulate matter depending on the properties of the contaminated organic material.