US 11,814,593 B1
Processes for hydroprocessing and cracking crude oil
Mansour Ali Al Herz, Dhahran (SA); Aaron Akah, Dhahran (SA); Qi Xu, Dhahran (SA); Lianhui Ding, Dhahran (SA); and Bander Al Ghamdi, West Dammam (SA)
Assigned to Saudi Arabian Oil Company, Dhahran (SA)
Filed by Saudi Arabian Oil Company, Dhahran (SA)
Filed on Dec. 12, 2022, as Appl. No. 18/064,488.
Int. Cl. C10G 69/04 (2006.01); B01J 29/40 (2006.01); B01J 35/02 (2006.01); B01J 21/04 (2006.01); B01J 21/08 (2006.01); B01J 21/16 (2006.01)
CPC C10G 69/04 (2013.01) [B01J 21/04 (2013.01); B01J 21/08 (2013.01); B01J 21/16 (2013.01); B01J 29/40 (2013.01); B01J 29/405 (2013.01); B01J 35/023 (2013.01); C10G 2300/1048 (2013.01); C10G 2300/202 (2013.01); C10G 2300/205 (2013.01); C10G 2300/301 (2013.01); C10G 2300/308 (2013.01); C10G 2300/4006 (2013.01); C10G 2300/4012 (2013.01); C10G 2400/20 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A process for upgrading a crude oil comprising:
contacting the crude oil with one or more hydroprocessing catalysts to produce a hydroprocessed effluent wherein the crude oil has an API gravity from 30 to 35; and
contacting the hydroprocessed effluent with a high-severity fluidized catalytic cracking (HS-FCC) catalyst composition in a high-severity FCC (HS-FCC) unit to produce cracked effluent comprising olefins, aromatic compounds, or both, wherein the HS-FCC unit operates at a temperature of greater than or equal to 580° C., a weight ratio of the HS-FCC catalyst composition to the crude oil of from 2:1 to 6:1, and a residence time of from 0.1 seconds to 60 seconds, wherein:
the HS-FCC catalyst composition comprises:
ultrastable Y-type zeolite (USY zeolite) impregnated with lanthanum;
nano-ZSM-5 zeolite impregnated with phosphorous, where the nano-ZSM-5 zeolite has an average particle size of from 0.01 μm to 0.2 μm;
an alumina binder;
colloidal silica; and
a matrix material comprising Kaolin clay.