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.

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.

A process for the production of sustainable aviation fuel (SAF) with low carbon intensity. The jet fuel is produced from the reaction of hydrogen from the electrolysis of water with captured carbon dioxide. The hydrogen and carbon dioxide are reacted to product a stream comprising carbon monoxide. Hydrogen and carbon monoxide are reacted to produce n-alkanes. Alkanes are hydroisomerized to produce sustainable aviation fuel with low carbon intensity.

A process for steam cracking a whole crude including a volatilization step performed to maintain a relatively large hydrocarbon droplet size. The process may include contacting a whole crude with steam to volatilize a portion of the hydrocarbons, wherein the contacting of the hydrocarbon feedstock and steam is conducted at an initial relative velocity of less than 30 m/s, for example. The resulting vapor phase, including volatilized hydrocarbons and steam may then be separated from a liquid phase comprising unvaporized hydrocarbons. The hydrocarbons in the vapor phase may then be forwarded to a steam pyrolysis reactor for steam cracking of the hydrocarbons in the vapor phase.

A continuous process for converting waste plastic into recycle for polypropylene polymerization is provided. The process integrates refinery operations to provide an effective and efficient recycle process. The process comprises selecting waste plastics containing polyethylene and polypropylene and then passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a refinery FCC unit, from which is recovered a liquid petroleum gas C.sub.3 olefin/paraffin mixture. The C.sub.3 paraffins and C.sub.3 olefins are separated into different fractions with a propane/propylene splitter. The C.sub.3 olefin fraction is passed to a propylene polymerization reactor. The C.sub.3 paraffin fraction is optionally passed to a dehydrogenation unit to produce additional propylene and then the resulting C.sub.3 olefin is passed to a propylene polymerization reactor. The heavy fraction of pyrolyzed oil is passed to an isomerization dewaxing unit to produce a lubricating base oil.

An integrated process and associated system for conversion of crude oil to value added petrochemicals. The process includes separating crude oil into light and heavy crude fractions and processing the heavy fraction in a solvent deasphalting unit and a delayed coker unit, and then providing the light fraction and selected effluents of the solvent deasphalting unit and the delayed coker unit to a hydrotreater. The process further includes separating the effluent of the hydrotreater to generate a C1 fraction passed to a methane cracker, a C2 fraction passed to an ethane steam cracker, a C3-C4 fraction passed to a dehydrogenation reactor, a hydrotreated light fraction passed to an aromatization unit, and a hydrotreated heavy fraction passed to a steam enhanced catalytic cracking unit. The process further includes separating effluents of the various unit operations into product streams including a BTX stream and a light olefin stream.

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 hydrotreated gas oil range intermediates from the vacuum gas oil hydroprocessing zone. Furthermore, vacuum residue is processed in a solvent deasphalting unit to produce deasphalted oil 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 hydrotreated gas oil range intermediates from the vacuum gas oil hydroprocessing zone. Furthermore, vacuum residue is processed in a solvent deasphalting unit to produce deasphalted oil as additional feed to the gas oil hydroprocessing zone.

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.

The present application relates to a process for treating gasoline, comprising the steps of: contacting a gasoline feedstock with a mixed catalyst and subjecting it to desulfurization and aromatization in the presence of hydrogen to obtain a desulfurization-aromatization product; optionally, splitting the resulting desulfurization-aromatization product into a light gasoline fraction and a heavy gasoline fraction; and, optionally, subjecting the resulting light gasoline fraction to etherification to obtain an etherified oil; wherein the mixed catalyst comprises an adsorption desulfurization catalyst and an aromatization catalyst. The process of the present application is capable of reducing the sulfur and olefin content of gasoline and at the same time increasing the octane number of the gasoline while maintaining a high yield of gasoline.