A system for steam cracking a whole crude that may include a volatilization device, a control system, a separator, and a steam pyrolysis reactor. The volatilization device may be configured to separate a vapor phase from a liquid phase. The control system may be configured to maintain a flow rate of the whole crude and steam, at an initial relative velocity of less than 30 m/s. The separator may be fluidly connected to the volatilization device and configured to separate the liquid phase into a second vapor phase, and a second liquid phase. The steam pyrolysis reactor may include a convection section and a steam pyrolysis heater section, the convection section configured to heat the vapor phase, the liquid phase, and the second vapor phase, and the steam pyrolysis heater section configured to steam crack hydrocarbons in the vapor phase thereby generating a cracked hydrocarbon product.

A system for steam cracking a whole crude that may include a volatilization device, a control system, a separator, and a steam pyrolysis reactor. The volatilization device may be configured to separate a vapor phase from a liquid phase. The control system may be configured to maintain a flow rate of the whole crude and steam, at an initial relative velocity of less than 30 m/s. The separator may be fluidly connected to the volatilization device and configured to separate the liquid phase into a second vapor phase, and a second liquid phase. The steam pyrolysis reactor may include a convection section and a steam pyrolysis heater section, the convection section configured to heat the vapor phase, the liquid phase, and the second vapor phase, and the steam pyrolysis heater section configured to steam crack hydrocarbons in the vapor phase thereby generating a cracked hydrocarbon product.

According to an embodiment disclosed, a feedstock hydrocarbon may be processed by a method which may include separating the feedstock hydrocarbon into a lesser boiling point hydrocarbon fraction and a greater boiling point hydrocarbon fraction, cracking the greater boiling point hydrocarbon fraction in a high-severity fluid catalytic cracking reactor unit to form a catalytically cracked effluent, cracking the lesser boiling point hydrocarbon fraction in a steam cracker unit to form a steam cracked effluent, and separating one or both of the catalytically cracked effluent or the steam cracked effluent to form two or more petrochemical products. In one or more embodiments, the feedstock hydrocarbon may include crude oil and one of the petrochemical products may include light olefins.

According to an embodiment disclosed, a feedstock hydrocarbon may be processed by a method which may include separating the feedstock hydrocarbon into a lesser boiling point hydrocarbon fraction and a greater boiling point hydrocarbon fraction, cracking the greater boiling point hydrocarbon fraction in a high-severity fluid catalytic cracking reactor unit to form a catalytically cracked effluent, cracking the lesser boiling point hydrocarbon fraction in a steam cracker unit to form a steam cracked effluent, and separating one or both of the catalytically cracked effluent or the steam cracked effluent to form two or more petrochemical products. In one or more embodiments, the feedstock hydrocarbon may include crude oil and one of the petrochemical products may include light olefins.

Disclosed herein is a phosphorus modified UZM-35 zeolite, methods of its preparation, and methods of its use in hydrocarbon conversion processes, e.g., as part of a catalyst component and/or as part of a catalyst composition. Catalyst components with phosphorus modified UZM-35, their methods of preparation, and their methods of use suitable for petroleum refining applications (e.g., hydrocarbon conversion processes such as fluid catalytic cracking and hydrocracking) are described herein. Also disclosed herein are catalyst compositions, which include phosphorus modified UZM-35 and catalyst components thereof along with at least one additional catalyst component. Methods of preparing and methods of using such catalyst compositions are also encompassed by the instant disclosure.

Disclosed herein is a phosphorus modified UZM-35 zeolite, methods of its preparation, and methods of its use in hydrocarbon conversion processes, e.g., as part of a catalyst component and/or as part of a catalyst composition. Catalyst components with phosphorus modified UZM-35, their methods of preparation, and their methods of use suitable for petroleum refining applications (e.g., hydrocarbon conversion processes such as fluid catalytic cracking and hydrocracking) are described herein. Also disclosed herein are catalyst compositions, which include phosphorus modified UZM-35 and catalyst components thereof along with at least one additional catalyst component. Methods of preparing and methods of using such catalyst compositions are also encompassed by the instant disclosure.

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 producing light aromatics, includes the steps of: i) contacting a feedstock comprising heavy aromatic(s) with a catalyst in a fluidized reactor for aromatics lightening reaction in the presence of hydrogen to obtain a product rich in C6-C8 light aromatic(s) and a spent catalyst, wherein the heavy aromatic is one or more selected from C9+ aromatics; ii) separating the resulted product rich in C6-C8 light aromatic(s) to obtain hydrogen, a non-aromatic component, C6-C8 light aromatic(s) and a C9+ aromatic component; and iii) recycling at least a part of the C9+ aromatic component to the fluidized reactor. The method has strong adaptability to feedstocks and high flexibility in operation and allows a long-period stable operation. The method can produce high-value light aromatics from heavy aromatics that are difficult to be treated and utilized.

The presently disclosed subject matter provides methods for producing olefins and/or aromatics from coker naphtha. In a non-limiting embodiment, a method for producing aromatics includes hydrogenating the coker naphtha stream in the presence of a first catalyst to remove diolefins and sulfur, if any, to obtain a hydrogenated stream and subjecting the hydrogenated stream to aromatization in the presence of a second catalyst to produce an aromatic-rich stream that includes benzene, toluene and xylene. In certain embodiments, a method for producing olefins includes hydrogenating the coker naphtha stream in the presence of a first catalyst to remove diolefins and sulfur, if any, to obtain a hydrogenated stream and subjecting the hydrogenated stream to catalytic cracking in the presence of a second catalyst to produce an olefin-rich stream that includes ethylene, propylene and aromatics.