Systems and processes are disclosed for producing petrochemical products, such as ethylene, propene and other olefins from crude oil in high severity fluid catalytic cracking (HSFCC) units. Processes include separating a crude oil into a light fraction and a heavy fraction, cracking the light fraction and heavy fraction in separation separate cracking reaction zones, and regenerating the cracking catalysts in a two-zone having a first regeneration zone for the first catalyst (heavy fraction) and a second regeneration zone for the second catalyst (light fraction) separate from the first regeneration zone. Flue gas from the first catalyst regeneration zone is passed to the second regeneration zone to provide additional heat to raise the temperature of the second catalyst of the light fraction side. The disclosed systems and processes enable different catalysts and operating conditions to be utilized for the light fraction and the heavy fraction of a crude oil feed.

A process for converting a hydrocarbon feed to olefins includes passing the hydrocarbon feed to a distillation system to separate the hydrocarbon feed to produce a light gas stream, a plurality of distillate fractions, and a residue. The process further includes passing at least one of the distillate fractions to a steam catalytic cracking system that includes at least one steam catalytic cracking reactor that is a fixed bed reactor containing a nano-zeolite cracking catalyst. The steam catalytic cracking system contacts the one or more of the plurality of distillate fractions with steam in the presence of the nano-zeolite cracking catalyst, which causes steam catalytic cracking of at least a portion of hydrocarbons in the at least one distillate fraction to produce a steam catalytic cracking effluent comprising the olefins.

A process for converting a hydrocarbon feed to olefins includes passing the hydrocarbon feed to a distillation system to separate the hydrocarbon feed to produce a light gas stream, a plurality of distillate fractions, and a residue. The process further includes passing at least one of the distillate fractions to a steam catalytic cracking system that includes at least one steam catalytic cracking reactor that is a fixed bed reactor containing a nano-zeolite cracking catalyst. The steam catalytic cracking system contacts the one or more of the plurality of distillate fractions with steam in the presence of the nano-zeolite cracking catalyst, which causes steam catalytic cracking of at least a portion of hydrocarbons in the at least one distillate fraction to produce a steam catalytic cracking effluent comprising the olefins.

In the hydrocracking process in accordance with the invention, which comprises a hydrocracking section, a high pressure hot separator and a fractionation section, upstream of the fractionation section, a stripper or reboiler column type separation column is added which treats at least a portion of the heavy effluent obtained from the high pressure hot separator. All or a portion of the bottom fraction from said column, which is rich in polynuclear aromatic compounds, is purged. At least a portion of the bottom fraction obtained from the fractionation section, which is constituted by unconverted products, is recycled to the reaction section.

In the hydrocracking process in accordance with the invention, which comprises a hydrocracking section, a high pressure hot separator and a fractionation section, upstream of the fractionation section, a stripper or reboiler column type separation column is added which treats at least a portion of the heavy effluent obtained from the high pressure hot separator. All or a portion of the bottom fraction from said column, which is rich in polynuclear aromatic compounds, is purged. At least a portion of the bottom fraction obtained from the fractionation section, which is constituted by unconverted products, is recycled to the reaction section.

A reactor system configured for efficiently removing contaminants (CCR, nickel, vanadium, nitrogen, sodium, iron, calcium, chlorine etc.) from a heavy portion of the crude oil. The products are routed to a common main fractionation section. The heavy feed with lower contaminants may then be processed in a fluid catalytic cracking (FCC) unit, the overall concept employing a fluid catalytic reaction platform with carbon rejection approach. Also disclosed is a reactor system for efficiently processing crude oil in a fluid catalytic cracking unit with a dual-reactor and dual catalyst system to maximize petrochemical building blocks such as ethylene, propylene, butylenes, BTX (benzene, toluene and xylene) rich naphtha from a variety of crude oils.

A reactor system configured for efficiently removing contaminants (CCR, nickel, vanadium, nitrogen, sodium, iron, calcium, chlorine etc.) from a heavy portion of the crude oil. The products are routed to a common main fractionation section. The heavy feed with lower contaminants may then be processed in a fluid catalytic cracking (FCC) unit, the overall concept employing a fluid catalytic reaction platform with carbon rejection approach. Also disclosed is a reactor system for efficiently processing crude oil in a fluid catalytic cracking unit with a dual-reactor and dual catalyst system to maximize petrochemical building blocks such as ethylene, propylene, butylenes, BTX (benzene, toluene and xylene) rich naphtha from a variety of crude oils.

High-quality graphite/needle grade coke is produced with reduced impurity levels and improved coefficient of thermal expansion using an integrated hydrotreatment, catalytic cracking and coking reaction sections, employing a combination of highly paraffinic hydrotreated VGO stream and aromatic CLO stream, which is thereafter processed in a delayed coking section.

A system includes a hydroprocessing zone configured to remove impurities from crude oil; a first separation unit configured to separate a liquid output from the hydroprocessing zone into a light fraction and a heavy fraction; an aromatic extraction subsystem configured to extract aromatic petrochemicals from the light fraction; and a pyrolysis section configured to crack the heavy fraction into multiple olefinic products.

A system includes a hydroprocessing zone configured to remove impurities from crude oil; a first separation unit configured to separate a liquid output from the hydroprocessing zone into a light fraction and a heavy fraction; an aromatic extraction subsystem configured to extract aromatic petrochemicals from the light fraction; and a pyrolysis section configured to crack the heavy fraction into multiple olefinic products.