STEAM CRACKING WITH NAPHTHA DEAROMATIZATION

BACKGROUND OF THE INVENTION

[oooi] This invention relates to a process for steam cracking of grade

and/or off-grade naphtha, and more particularly to steam or catalytic cracking

with dearomatization of the naphtha feed for the production of ethylene and

propylene.

[0002] Approximately half of the world's ethylene capacity is produced by

the steam cracking of naphtha feed streams. For purposes of this application,

naphtha has a boiling range from C5 to 200 ⁰ C, and is generally produced by the

fractionation of crude oil. Naphtha can comprise light and heavy naphtha.

Light naphtha is typically characterized by a boiling point of less than 100 ⁰ C

and heavy naphtha is typically characterized by a boiling point of between 100°

and 200 ⁰ C. Generally, heavy naphtha has a lower paraffin and higher aromatics

content than light naphtha, making it less suitable as feedstock in the production

of ethylene without upgrading. Naphtha steam cracking suitability is

determined by the composition of paraffins, olefins, naphthenes and aromatics,

each of which can be used to produce ethylene and propylene. Aromatics are

generally not a desired feed component in the production of ethylene and

propylene, and therefore the aromatics content of the naphtha feed can play an

important role in determining suitability for cracking. During steam cracking,

the aromatic compounds typically produce undesirable fuel oil. Polymers

synthesized from aromatic compounds are often responsible for quench oil

tower fouling, which can result in unscheduled shutdowns of the steam crackers.

[0003] Naphtha streams rich in paraffins and low in aromatics are

generally preferred for steam cracking. For example, in Eastern Asia, the

design and operation of crackers requires a minimum paraffin content of

approximately 65% by weight, typically specified as open spec naphtha (OSN).

Most Middle East naphtha feedstock complies with the Eastern Asia OSN

specifications. However, much of the non-Middle East sourced naphtha feeds

are poor in paraffins and rich in aromatics, resulting in compositions which do

not comply with the OSN specifications and therefore are not useful as steam

cracker feeds in the prior art steam cracking processes.

[0004] Heavy naphthas recovered around the world can vary greatly in the

amount of total paraffins and aromatics. The paraffins content can range

between approximately 27% and 70% by volume, the naphthenes content

between approximately 15% and 60% by volume, and the aromatics content

between 10 and 36% by volume. One example of grade naphtha is Basrah

Heavy naphtha produced in Iraq, having a boiling point range between 65° and

175 ⁰ C, a total paraffin content of approximately 69% by volume, a naphthene

content of approximately 21% by volume, and an aromatics content of

approximately 10% by volume. In comparison, an example of off-grade

naphtha is Mubarak crude produced in the United Arab Emirates, having a

boiling point range between 104° and 182 ⁰ C, a total paraffin content of

approximately 50% by volume, a naphthenes content of approximately 30% by

volume, and an aromatics content of approximately 20% by volume.

[0005] For purposes of this application, naphtha which meets OSN

specification will be termed "grade" naphtha, while naphtha not meeting OSN

specifications (typically a naphtha feed rich in aromatics and/or paraffin poor)

will be termed here as "off grade" naphtha.

[0006] In US Pat. No. 6,210,561, Bradow et al. disclose a method for

steam cracking a hydrocarbon feed wherein the hydrocarbon feed is treated in a

hydrotreating zone to remove nitrogen and sulfur compounds. The hydrotreated

stream is then supplied to an aromatics saturation zone prior to cracking of the

hydrocarbon effluent.

[0007] In US Pat. No. 6,149,800, Iaccino et al. disclose a method for

increasing olefin yields from heavy hydrocarbon feedstock. The process

comprises hydroprocessing a feedstock in the boiling range of distillate and

above, wherein the feedstock and hydrogen treat gas flow countercurrent to one

another.

[0008] Patents of note include US Pat. Nos. 4,647,368; 4,927,525;

5,053,579; 5,292,976; 5,396,010; 5,414,172; 5,643,441; 5,685,972; and

5,865,988, disclosing naphtha upgrading; US Pat. Nos. 4,877,581 and

4,839,023, disclosing gas oil upgrading; US Pat Nos. 5,045,174; 5,906,728; and

6,149,800, disclosing the upgrading of stream cracker feeds; and 6,210,561;

6,407,301; and 6,441,263, each of which is herein incorporated by reference.

[0009] The present invention also provides a process whereby off-grade

naphtha streams can be upgraded for use as steam cracker feedstock by

removing the aromatics from the off-grade naphtha stream. By removing the

aromatics from some naphtha feeds, the paraffin content can be increased to at

least 65%, thereby meeting the OSN specifications. In some cases

dearomatized naphtha may be suitable for steam cracking even though it may

not meet OSN specifications.

SUMMARY OF THE INVENTION

[ooio] The present invention provides a naphtha cracking method where

the feedstock can include an off-grade naphtha stream. The naphtha feedstock

can be dearomatized for feed to the cracking process. The naphtha feedstock

dearomatization can be conveniently integrated with aromatics extraction from

the cracker effluent to increase aromatics production.

[ooii] In one embodiment of the present invention, an olefins process for

steam cracking naphtha is provided. The process includes: (a) recovering

olefins and pyrolysis gasoline streams from a steam cracking furnace effluent,

(b) hydrogenating the pyrolysis gasoline stream and recovering a C ₆ - C ₈ stream

therefrom, (c) hydrotreating an aromatics-containing naphtha stream to obtain a

naphtha feed stream lean in nitrogen, sulfur, arsenic, lead, or a combination

thereof, (d) dearomatizing the C ₆ - C ₈ stream with the naphtha feed stream in a

common aromatics extraction unit to obtain a raffϊnate stream, and (e) feeding

the raffϊnate stream to the steam cracking furnace.

[0012] The aromatics-containing naphtha stream can comprise a paraffins

content of less than 65 weight percent. The aromatics-containing naphtha

stream can comprise an aromatics content of 10 weight percent or more. The

steam cracking furnace effluent can comprise a propylene to ethylene weight

ratio from 0.3 to 0.8, i.e. the same cracker severity as grade naphtha feed, or in

another embodiment, a propylene to ethylene weight ratio from 0.4 to 0.6. The

process can further comprise feeding a second naphtha stream to the steam

cracking furnace, wherein the second naphtha stream comprises 65 weight

percent or more paraffins and no more than 10 weight percent aromatics. The

pyrolysis gasoline can be hydrogenated using commercial hydrogenation

processes, such as for example, those offered by IFP, UOP, BASF, and others

The fouling in a quench oil tower receiving the steam furnace cracking effluent

can be inhibited. The process can further comprise recovering ethane and

propane from the steam cracking furnace effluent and recycling the recovered

ethane and propane to the steam cracking furnace. The process can further

comprise recovering a C5 olefins stream from the pyrolysis gasoline

hydrogenation and recycling the C5 olefins stream to the steam cracking

furnace. The process can further comprise hydrotreating a second naphtha

stream, wherein the second naphtha stream comprises 65 weight percent or

more paraffins and no greater than 10 weight percent aromatics. The aromatics

containing naphtha stream can comprise heavy naphtha.

[0013] In another embodiment, the invention provides an olefins process

for steam cracking a naphtha stream comprising aromatics. The process

includes the steps of: (a) recovering olefins and pyrolysis gasoline streams from

a steam cracking furnace effluent, (b) hydrogenating the pyrolysis gasoline

stream and recovering a C6-C8 stream therefrom, (c) hydrotreating a heavy

naphtha stream comprising aromatics to obtain a heavy naphtha stream lean in

nitrogen, sulfur, arsenic, lead, or a combination thereof, (d) reforming the

hydrotreated heavy naphtha stream in a catalytic reformer to obtain a reformate

comprising aromatics, (e) dearomatizing the C6-C8 stream with the reformate in

a common aromatics unit to obtain a mixed stream comprising C6-C8 raffinate,

reformate raffinate, and a dearomatized heavy naphtha stream, and (e) feeding

the mixed stream to the steam cracking furnace.

[0014] The process can further include hydrotreating a second aromatics-

containing heavy naphtha stream in a second hydrotreater to obtain a second

hydrotreated heavy naphtha stream lean in nitrogen, sulfur, arsenic, lead, or a

combination thereof; and dearomatizing the heavy naphtha stream, the

reformate and the C6-C8 stream in the common aromatics extraction unit. The

process can further include supplying a portion of the hydrotreated heavy

naphtha stream to the reformer, and dearomatizing the balance of the

hydrotreated heavy naphtha stream with the C6-C8 stream and the reformate

raffinate. The process can further include reforming a hydrocracker naphtha

stream with a portion of the hydrotreated heavy naphtha in the catalytic

reformer to obtain a reformate stream.

[0015] In another embodiment of the present invention, an olefins process

unit for steam cracking an aromatics-containing naphtha stream is provided.

The process unit includes: (a) one or more steam cracking furnaces to produce

a pyrolysis effluent, (b) a recovery unit to recover olefins and pyrolysis gasoline

streams from the pyrolysis effluent, (c) a gasoline hydrogenation unit to

hydrogenate the pyrolysis gasoline stream and recover a C ₆ - C ₈ stream, (d) a

hydrotreating unit to remove nitrogen, sulfur, arsenic, lead, or a combination

thereof from an aromatics-containing naphtha stream to obtain a naphtha feed

stream, (e) a common aromatics extraction unit to dearomatize the C ₆ - C ₈

stream together with the naphtha feed stream to obtain a raffinate stream, and (f)

a line to feed the raffinate stream with dearomatized naphtha to the steam

cracking furnace.

[0016] The olefins process unit can further comprise lines to recycle

ethane and propane streams from the recovery unit to the steam cracking

furnace. The olefins process unit can further comprise a line to recycle a C ₅

olefins stream from the gasoline hydrogenation unit to the steam cracking

furnace.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] For a more detailed description of the illustrated embodiments of

the present invention, reference will now be made to the accompanying

drawings, wherein:

[ooi8] Fig. 1 is a block flow diagram of a prior art naphtha based steam

cracker having an aromatics extraction unit for treating the furnace effluent.

[0019] Fig. 2 is a block flow diagram of a naphtha based steam cracking

unit having an integrated aromatics extraction unit wherein furnace feed

comprising off-grade naphtha can be supplied to an aromatics extraction unit.

[0020] Fig. 3 is a block flow diagram of a naphtha based steam cracking

unit having an integrated aromatics extraction unit wherein a portion of the

furnace feed is an off-grade naphtha supplied to an aromatics extraction unit.

[0021] Fig. 4 is a block flow diagram of a naphtha based steam cracking

unit having an integrated aromatics extraction unit wherein a portion of the

naphtha stream is supplied to a dearomatizer.

[0022] Fig. 5 is a block flow diagram of a naphtha based steam cracking

unit having an integrated hydrotreater and dearomatization unit for the removal

of aromatics from a heavy naphtha feed.

[0023] Fig. 6 is a block flow diagram of a naphtha based steam cracking

unit having an aromatics removal unit, wherein a heavy naphtha feed is supplied

to a catalytic reformer upstream from the aromatics extraction unit.

[0024] Fig. 7 is a block flow diagram of a naphtha based steam cracking

unit having an integrated aromatics removal unit, wherein a portion of a heavy

naphtha feed is supplied to a catalytic reformer upstream from the aromatics

extraction unit, and a portion of the heavy naphtha feed bypasses the catalytic

reformer.

[0025] Fig. 8 is a block flow diagram of a variation of the naphtha based

steam cracking unit of Fig. 7, wherein a hydrocracker naphtha feed is supplied

to the catalytic reformer with a portion of the heavy naphtha feed.

[0026] Fig. 9 A is a block flow diagram of a naptha based ethylene plant

wherein ethylene plant capacity is increased by increasing naphtha feed to the

ethylene plant.

[0027] Fig. 9B is a block flow diagram of a naphtha based ethylene plant

wherein ethylene plant capacity is increased by increasing naphtha feed to the

ethylene plant and supplying a dearomatized heavy naphtha stream to the

ethylene plant.

DETAILED DESCRIPTION OF THE INVENTION

[0028] Detailed embodiments of the present invention are disclosed

herein. However, it is understood that the disclosed embodiments are merely

exemplary of the present invention, which can be embodied in various forms

and are not to be construed as limitations of the invention. Specific structural,

functional and process details disclosed herein are not intended to be limiting,

but are merely illustrations that can be modified within the scope of the attached

claims.

[0029] In addition to ethylene and propylene, naphtha based crackers can

produce various by-products which can contain significant amounts of

aromatics, such as for example, raw pyrolysis gasoline (C5 to 200 ⁰ C), which

frequently can have an end boiling point similar to the naphtha feed. As steam

crackers increase in size, dedicated facilities are typically integrated with the

steam cracker to recover aromatic compounds. In recovering of aromatics from

pyrolysis gasoline, the raw pyrolysis gasoline can be hydrogenated to saturate

di-olefins and olefins, and the saturated pyrolysis gasoline can then be fed to an

aromatics recovery unit.

[0030] Referring to the drawings, wherein like referenced parts have like

numerals, the design for a prior art naphtha based steam cracker with an

aromatics extraction unit is shown in Fig. 1. The process can comprise a feed

stream 102, a furnace 112, and a separation and recovery area 116. A

feedstream of grade naphtha 102 is fed to furnaces 112 for cracking. Furnace

effluent is supplied via line 114 to a recovery section 116, which can comprise

various known means for the separation and recovery of mixed hydrocarbon

streams, including but not limited to, fractionation, distillation, and the like.

The separation and recovery process 116 can produce a variety of streams

including hydrogen 118, fuel gas 120, ethylene 122, propylene 124, C4 mixed,

and fuel oil 140 for recovery and export, and ethane 110 and propane 108

streams, which can be recycled to the furnace(s). An aromatics stream 128 can

be recovered, and processed in a gasoline hydrogenation unit 130 producing a

C5 olefin stream 106 which can be recycled to the furnace 112 as steam

cracking feed, a C9+ fraction which can be recovered, and a hydrogenated C6-

C8 stream 132, which can be supplied to an aromatics extraction unit 136. The

aromatics extraction unit can produce an aromatics stream 140 for recovery and

a C6-C8 raffinate stream 104, which can be recycled to the furnaces 112.

[0031] Preferably, the C6-C8 fraction of the furnace effluent can be

hydrogenated in the two stage gasoline hydrogenation unit 130 to saturate

diolefins in the first stage and to convert olefins to saturated compounds and

remove of sulfur and nitrogen contaminants in the second stage. While single

stage gasoline hydrogenation units are used in the art and can be used in the

present invention, a two stage hydrogenation unit is preferable to achieve more

complete removal of sulfur and nitrogen. Hydrogenation of the C6-C8 fraction

is relatively expensive as removal of nitrogen is generally expensive.

Hydrogenation of C6-C8 fraction is typically necessary to meet the sulfur

specification requirements of aromatic products such as high purity benzene or

nitration grade toluene. The second stage hydrogenated C6-C8 fraction

supplied to the aromatics unit 136 can comprise benzene, toluene and C8

aromatics, as well as paraffins and naphthenes.

[0032] The aromatics extraction unit 136 can be provided to remove

aromatics from the second stage hydrogenated C6-C8 fraction 132. The

primary function of the aromatics extraction unit 136 is to separate aromatics,

such as for example, benzene, toluene, and/or C8 aromatics, from the non-

aromatic compounds which are identified as C6-C8 raffmate, typically

comprising C6-C8 paraffins and naphthenes. For purposes of the specification

and claims, raffinates comprise the portion of the feed which is not extracted

and removed by the aromatics extraction unit, and may contain negligible

undesired aromatics as well as hydrocarbons desired as feed to the cracking

furnace 112. The C6-C8 raffinates can be recycled to the furnace for additional

steam cracking. Separation of aromatics from non-aromatics can be achieved

using conventional liquid-liquid extraction techniques and/or extractive

distillation, as is known in the art. Commercially practiced technologies for the

extraction of aromatics include: UOP-Sulfolane, UOP-Udex, UOP-Tetra,

Uhde-Morphylex, IFP-DMSO, Lurgi-Arosolvan, Snamprogetti-FM, GTC-ED,

and the like. Sample patents relating to the extraction of aromatics include US

Pat. Nos. 3,944,483; 5,310,480; 6,124,514; and 6,375,802; each of which is

hereby incorporated herein by reference.

[0033] One embodiment of the present invention is shown in Figure 2,

wherein a naphtha dearomatization process can be integrated with the naphtha

steam cracker for the upgrading of an off-grade naphtha feed for the production

of light olefins. The process comprises a naphtha feed stream 103, a cracking

furnace 112, and a separation and recovery area 116. A feed stream of naphtha

103 can be supplied to a naphtha hydrotreater 142, and fed to the aromatics

extraction unit 136 via line 144. The aromatics extraction unit 136 can produce

an aromatics stream 138 for collection, and a stream comprising dearomatized

naphtha 104. The dearomatized naphtha stream 104 can be supplied to furnace

112 to produce a hydrocarbon effluent 114, which is supplied to separation and

recovery area 116. The conventional separation and recovery area 116 can

produce hydrogen 118, fuel gas 120, ethylene 122, propylene 126 and fuel oil

140 streams for collection. An ethane stream 110 and propane stream 108 can

be separated from the furnace effluent 114 and recycled to the cracking furnace

112. A pyrolysis gasoline stream 128 can be supplied to a two stage gasoline

hydrogenation unit 130, which produces a C5 fraction for recycle to the furnace

112, a C6-C8 fraction for supply to the aromatics extraction unit 136 via line

132, and a C9+ fraction for collection via line 134. The aromatics extraction

unit 136 can produce an aromatics stream 138 for removal from the process and

a C6-C8 raffinate stream 104, comprising C6-C8 paraffin and naphthenes,

which can be combined with the dearomatized naphtha stream for supply to the

furnace.

[0034] Naphtha dearomatization can include subjecting naphtha stream to

hydrotreating in a naphtha hydrotreater unit to remove impurities. As shown in

Fig. 2, the hydrotreated naphtha stream 144 can be mixed with a hydrogenated

C6-C8 fraction 132 from the gasoline hydrogenation unit 130 and fed to the

aromatics extraction unit 136. The aromatics extraction unit can produce a

composite stream containing C6-C8 raffmate and dearomatized naphtha, and

can be sent to the furnaces for steam cracking.

[0035] Depending on market conditions and availability, access to grade

naphtha may not be sufficient to produce ethylene at maximum plant capacity.

The shortfall in production can be made up by supplying off-grade naphtha as

all or a portion of the required cracking feed, utilizing the present

dearomatization process. Because of the lower price of off-grade naphtha,

dearomatization and steam cracking of an off-grade feed can be highly

profitable. Existing plants designed to operate with grade naphtha can be

retrofitted to accommodate heavy naphtha feeds.

[0036] As shown in Fig. 3, an ethylene plant configuration for the

combined use of grade and off-grade naphtha is similar to the ethylene plant of

Fig. 2, with the addition of a naphtha feedstream supplied directly to the

furnace. Figure 3 shows a process for the production of olefins, wherein both

grade and off-grade naphtha can be supplied as feed. The process can comprise

a grade naphtha feed stream 102, an off-grade naphtha feed stream 103, a

cracking furnace 112, and a separation and recovery area 116. A feedstream of

grade naphtha 102 is fed to conventional furnaces 112 for cracking. Furnace

effluent is supplied via line 114 to a recovery section 116, which can comprise

various known means for the separation and recovery of mixed hydrocarbon

streams. The separation and recovery process 116 can produce a variety of

streams including hydrogen 118, fuel gas 120, ethylene 122, propylene 124,

mixed C4, and fuel oil 140 for recovery and export, and can also produce ethane

110 and propane 108 streams, which can be recycled to the furnace 112 as a

feedstream. A pyrolysis gasoline stream 128 can be recovered, and processed in

two stage gasoline hydrogenation unit to produce a C5 olefin stream 106, which

can be recycled to the furnace 112, a C9+ fraction which can be recovered, and

a C6-C8 stream 132, which can be supplied to an aromatics extraction unit 136.

The off-grade naphtha stream 103 can be supplied to naphtha hydrotreater 142,

and then supplied via line 144 to the aromatics extraction unit 136, where it is

combined with the C6-C8 stream 132. The aromatics extraction unit 136

produces an aromatics stream 138 for collection and a stream 104 comprising

dearomatized naphtha and C6-C8 raffinate for supply to the furnace 112.

[0037] In a similar fashion, grade naphtha feed can be supplied to a

hydrotreater and the aromatics extraction unit, as shown in Figure 4, to increase

the yield of the overall process. Figure 4 shows a process with grade naphtha

dearomatization to increase yield. The process can comprise a grade naphtha

feed stream 102, a furnace 112, and a separation and recovery area 116. A

feedstream of grade naphtha 102 is fed to furnaces 112 for cracking. A portion

of the grade naphtha can be supplied to a naphtha hydrotreater 142 and

aromatics extraction unit 136 prior to being fed to the furnace 112. Furnace

effluent is supplied via line 114 to a recovery section 116, which can comprise

various known means for the separation and recovery of mixed hydrocarbon

streams. The separation and recovery process 116 can produce a variety of

streams including hydrogen 118, fuel gas 120, ethylene 122, propylene 124,

mixed C4, and fuel oil 140 streams for recovery, and can also produce ethane

110 and propane 108 streams, which can be recycled to the furnaces. A

pyrolysis gasoline stream 128 can be recovered, and processed in a two stage

gasoline hydrogenation unit to produce a C5 olefin stream 106 which can be

recycled to the furnace 112, a C9+ fraction which can be recovered, and a C6-

C8 stream 132 which can be supplied -to an aromatics extraction unit 136 where

it is combined with the hydrotreated naphtha stream 144. The aromatics

extraction unit can produce an aromatics stream 140 for collection and a stream

104 comprising C6-C8 raffmate and dearomatized naphtha, which can be

recycled to the furnaces 112 for cracking.

[0038] Integrating heavy naphtha dearomatization can have further

advantages. In many petrochemical complexes, according to an embodiment of

the invention, the steam cracker can be integrated with the aromatics production

as shown in Fig. 5, where the aromatics extraction unit is common to both units.

The process can comprise a feed stream 102, a furnace 112, and a separation

and recovery unit 116. A feedstream of grade naphtha 102 can be fed to

furnaces 112 for cracking to produce an effluent which can be supplied to the

recovery and separation area 116 via line 114. The recovery and separation

process can comprise a variety of known techniques, as described within this

application, to produce a variety of streams including hydrogen 118, fuel gas

120, ethylene 122, propylene 124, a mixed C4 stream, and a fuel oil 140 for

recovery. The recovery and separation can also recover streams of ethane 110

and propane 108 for recycle as feedstreams to the furnace. A pyrolysis gasoline

stream can be supplied from the recovery and separation area 116 to a two stage

gasoline hydrogenation unit 130 via line 128 to produce a C5 olefin fraction 106

that can also be recycled to the furnace 112 for further cracking. The second

hydrogenation stage can produce a C6-C8 fraction 132, and a C9+ fraction 134.

The C6-C8 fraction 132 can comprise aromatics, paraffins, and naphthenes, and

can be supplied to an aromatics extraction unit 136. A feed stream of heavy or

off-grade naphtha 105 can be supplied to a naphtha hydrotreater 142, and

supplied via line 146 to catalytic reformer 148 to produce a reformate which can

be supplied via line 149, where it is fed with the C6-C8 fraction 132 from the

pyrolysis gasoline hydrogenation unit 130, to the aromatics extraction unit 136.

The aromatics extraction unit 136 can produce an aromatics stream 138 for

collection, and a furnace feed line 104 comprising C6-C8 raffinate, reformate

raffinate, and dearomatized heavy naphtha.

[0039] This arrangement of the invention can be easily adapted to

integrate an additional heavy naphtha stream for dearomatization, followed by

ethylene production, as shown in the Fig. 6, wherein a second heavy naphtha

feedstream can be hydrotreated in a separate naphtha hydrotreater unit 143, and

then fed to the aromatics extraction unit 136, along with the steam cracker C6-

C8 fraction 132 and the reformate. The process can comprise a feed stream

102, a furnace 112, and a separation and recovery unit 116. A feedstream of

grade naphtha 102 can be fed to furnaces 112 for cracking to produce an

effluent which can be supplied to the recovery and separation area 116 via line

114. The recovery and separation process can comprise a variety of known

techniques, as described within this application, to produce a variety of streams

including hydrogen 118, fuel gas 120, ethylene 122, propylene 124, a mixed C4

stream, and a fuel oil 140 for recovery. The recovery and separation can also

recover streams of ethane 110 and propane 108 for recycle to the furnaces. A

pyrolysis gasoline stream can be supplied from the recovery and separation area

116 to a two stage gasoline hydrogenation unit 130 via line 128 to produce a C5

olefin fraction 106 that can be recycled to the furnace 112 for further cracking.

The second hydrogenation stage can produce a C6-C8 fraction 132, and a C9+

fraction 134. The C6-C8 fraction 132 can be supplied to an aromatics

extraction unit 136. A feed stream of heavy naphtha 105 can be supplied to a

naphtha hydrotreater 142, and supplied via line 146 to catalytic reformer 148 to

produce a reformate which can be supplied via line 149, where it is combined

with the C6-C8 fraction 132 from the pyrolysis gasoline hydrogenation unit

130, to the aromatics extraction unit 136. A second heavy naphtha stream 107

can be supplied to a second naphtha hydrotreater 143, and via line 144 to be fed

with the C6-C8 fraction 132 to the aromatics extraction unit 136. The heavy

naphtha streams 105, 107 can be or include an off-grade naphtha, if desired.

The aromatics extraction unit 136 produces an aromatics stream 138 for

collection, and a stream in furnace feed line 104 comprising C6-C8 raffmate,

reformate raffmate, and dearomatized heavy naphtha.

[0040] Further integration can be achieved by combining the two separate

heavy naphtha streams 105, 107 from the Fig. 6 configuration, and supplying to

a single hydrotreater 142, as shown in the Fig. 7, thereby reducing equipment

and maintenance costs. As shown in Fig. 7, a portion of the hydrotreated heavy

naphtha required for the steam cracker can bypass the catalytic reformer 148 for

supply to the aromatics extraction unit 136. The process can comprise a feed

stream 102, a furnace 112, and a separation and recovery unit 116. A

feedstream of grade naphtha 102 can be fed to furnaces 112 for cracking to

produce an effluent which is supplied to the recovery and separation area 116

via line 114. The recovery and separation process can comprise a variety of

known techniques, as described within this application, to produce a variety of

streams including hydrogen 118, fuel gas 120, ethylene 122, propylene 124, a

mixed C4 stream, and a fuel oil 140 for recovery. The recovery and separation

can also recover streams of ethane 110 and propane 108 for recycle to the

furnaces. A pyrolysis gasoline stream 128 can be supplied from the recovery

and separation area 116 to a two stage gasoline hydrogenation unit 130 to

produce a C5 olefin fraction 106 that can be recycled to the furnace 112 for

further cracking. The second hydrogenation stage can produce a C6-C8 fraction

132, and a C9+ fraction 134. The C6-C8 fraction 132 can comprise paraffins,

naphthenes, and aromatics, and can be supplied to an aromatics extraction unit

136. A first feed stream of heavy naphtha 105 and a second stream of heavy

naphtha 107 can be supplied to a naphtha hydrotreater 142. A first portion of

the hydrotreater 142 effluent can be supplied via line 146 to catalytic reformer

148 to produce a reformate which can be supplied via line 149 to the aromatic

extractions unit 136. A second portion of the hydrotreater effluent 142 can

bypass the reformer 148 and can be supplied via line 147 to line 132 where it is

combined with the C6-C8 fraction 132 from the pyrolysis gasoline

hydrogenation unit 130, and then supplied to the aromatics extraction unit 136

where it is combined with the reformate. The heavy naphtha streams 105, 107

can alternatively be supplied with an off-grade naphtha is desired. The

aromatics extraction unit 136 can produce an aromatics stream 138 for

collection and a furnace feedstream 104 comprising C6-C8 raffinate, reformate

raffmate, and dearomatized heavy naphtha.

[0041] In some integrated ethylene-aromatics complexes, the catalytic

reformers can process both heavy naphtha and hydrocracker naphtha, as shown

in Fig. 8. Hydrocracker naphtha is usually of a higher quality than the heavy

naphtha. The process can comprise a feed stream 102, a furnace 112, and a

separation and recovery unit 116. A feedstream of grade naphtha 102 can be

supplied to furnaces 112 for cracking to produce an effluent which is supplied to

the recovery and separation area 116 via line 114. The recovery and separation

process can comprise a variety of known techniques, as described within this

application, to produce a variety of streams including hydrogen 118, fuel gas

120, ethylene 122, propylene 124, a mixed C4 stream, and fuel oil 140 for

recovery. The recovery and separation can also recover streams of ethane 110

and propane 108 for recycle to the furnaces. A pyrolysis gasoline stream 128

can be supplied from the recovery and separation area 116 to a two stage

gasoline hydrogenation unit 130 to produce a C5 olefin fraction 106 that can be

recycled to the furnace 112 for further cracking. The second hydrogenation

stage can produce a C6-C8 fraction 132 comprising paraffins, naphthenes and

aromatics, and a C9+ fraction 134. The C6-C8 fraction 132 can be supplied to

an aromatics extraction unit 136. A feed stream of heavy or off-grade naphtha

105 can be supplied to a naphtha hydrotreater 142, and all or a portion of the

hydrotreated heavy naptha can be supplied via line 146 to catalytic reformer

148. All or a portion of the hydrotreated heavy naphtha can bypass the catalytic

reformer 148 via line 147, and combine with the C6-C8 fraction 132 for supply

to the aromatics extraction unit 136. The hydrotreater effluent can be combined

with a hydrocracker naphtha feed stream 109 and supplied to the reformer 148

to produce a reformate. The reformate can be supplied via line 149, where it is

combined with the C6-C8 fraction 132 from the pyrolysis gasoline

hydrogenation unit 130 and the hydrotreated heavy naphtha 147, and supplied

via 149 to the aromatics extraction unit 136. The aromatics extraction unit 136

can produce an aromatics stream 138 for collection, and a furnace feed line 104

comprising C6-C8 raffinate, reformate raffinate, and dearomatized heavy

naphtha for cracking.

[0042] Dearomatization of the heavy naphtha can be useful in the case

where the expansion of ethylene production in an integrated ethylene-aromatics

complex is desired, as shown in Figs. 9 A and 9B. As shown in Fig. 9 A, the

base case ethylene plant comprises a refinery 204, an ethylene plant 224, and an

aromatics extraction unit 220. Crude oil 202 is supplied to the refinery,

producing streams of naphtha 206, heavy naphtha 208, and hydrocracker

naphtha 210. Heavy naphtha 208 is -supplied to naphtha hydrotreater 212 and

the hydrotreated naphtha is supplied via line 210 to a catalytic reformer 216

where the hydrotreated naphtha is combined with hydrocracker naphtha

supplied via 210. The reformer produces a reformate 218, which can be

supplied to the aromatics recovery unit 220. The aromatics recovery unit 220

produces a raffinate stream 222 and an aromatics stream 230. The ethylene

plant is supplied with grade naphtha 206 from the refinery and raffinate stream

222 to produce an ethylene product stream 226. The ethylene plant also

produces a C6-C8 fraction 228 which can be hydrogenated (not shown) and

supplied to combine with the reformate 218 in the aromatics recovery unit 220.

To increase the ethylene capacity of the base case ethylene plant by 50%, crude

feed to the refinery is increased by 50%.

[0043] Dearomatization of a heavy naphtha feed can provide an alternate

means to increasing the ethylene capacity of an integrated ethylene-aromatics

plant, as shown in Fig. 9B. The operation for the ethylene-aromatics plant

shown in Fig. 9B is the same as that for the plant shown in Fig. 9A and

described above. To increase ethylene capacity of the plant, a portion of the

hydrotreated heavy naphtha from line 214 bypasses the catalytic reformer via

line 215. The amount of hydrotreated heavy naphtha supplied to line 215 varies

with the properties and composition of the heavy naphtha feed, but desirably

can be calculated to account for a predetermined increase in the ethylene

capacity of the plant, such as for example, a 10% increase in plant capacity.

Reformate from reformer 220 and dearomatized heavy naphtha 215 are

combined with a hydrogenated C6-C8 fraction 228 and supplied to the

aromatics recovery unit 220, to produce an aromatics stream 230 and a mixed

raffϊnate and dearomatized heavy naphtha stream 222 for supply to the ethylene

plant 224. To increase total capacity by 10%, crude feed to the refinery is

increased by 36%. Dearomatization of heavy naphtha can provide an increase

in ethylene capacity of the plant by approximately 10%, thus providing a total

increase in plant capacity of 150%. Excess heavy naphtha can be supplied to

provide increased ethylene capacity of greater than 10%, and crude feed

requirements can be reduced accordingly.

[0044] Naphtha feeds, whether grade or off-grade, often contain impurities

which may present problems in ethylene production. Refineries typically utilize

hydrotreating techniques to remove impurities present in the feedstock to

protect catalytic reforming catalyst. Naphtha hydrotreaters are generally

designed to produce hydrotreated naphtha streams having the following

maximum allowable contaminant levels:

Contaminant Maximum level

Sulfur 1 wt ppm

Nitrogen 0.5 wt ppm

Lead 10 wt ppb

Arsenic 2 wt ppb

Water 10 wt ppm

Chloride 1 wt ppm

Use of current state of the art naphtha hydrotreaters may result in lower levels

of contaminants and can include the removal of additional impurities. The

contaminant levels noted above are generally considered acceptable for steam

cracking feeds. Advantageously, the dearomatization process removes the bulk

of the contaminants and provides a contaminant free dearomatized naphtha

stream.

[0045] If the naphtha feed contains arsenic at a greater concentration than

given above, the ethylene plant must include an arsenic removal system, such as

for example, guard beds upstream from the hydrogenation units. By removing

contaminants with the hydrotreater, the ethylene plant can be designed without

separate contaminant removal systems, resulting in decreased construction and

maintenance costs.

[0046] Because the dearomatized naphtha will have a low nitrogen

content, the steam cracking byproduct raw pyrolysis gasoline will also have a

low nitrogen content. The second stage hydrogenation of the raw pyrolysis

gasoline may be less expensive due to a low severity design. In the case where

100% of the naphtha feed is supplied to both the hydrotreater and

dearomatization units prior to cracking, the second stage of the gasoline

hydrogenation unit may be designed for the removal of low level, such as for

example at the part per billion (ppb) level, or for operation at low severity. In

the case where a portion of the naphtha feed is supplied to both the hydrotreater

and dearomatization units prior to cracking, lower severity nitrogen removal

may be possible. However, while the dearomatized naphtha may have a lower

sulfur content, sulfur may be added to facilitate steam cracking, and may require

removal in th& second stage of the gasoline hydrogenation unit.

[0047] Dearomatization of the naphtha can also reduce quench oil tower

fouling. Polymers of styrene, indene and di-vinyl benzene are believed to

contribute to quench oil tower fouling. Styrene is a product of the

dehydrogenation of ethylbenzene. Indene can be produced by condensation

reactions involving aromatic compounds. Divinyl benzene can be formed by

the dehydrogenation of diethyl benzene. Polynuclear heavy aromatics formed

by condensation reactions and present in the fuel oil streams can be responsible

for fouling the bottom of the quench oil tower. Thus, removal of the aromatics

from the steam cracker feed ^" can reduce the formation of the aromatic

compounds responsible for the quench oil tower fouling.

[0048] Reduction of quench oil tower fouling rates can result in longer run

lengths and less frequent maintenance of the towers. Aromatics may still be

formed due to the cracking reactions, but formation of compounds believed to

cause fouling will be greatly reduced. Chemical additives designed to dissolve

the polymers responsible for the quench oil tower fouling are known in the art

and can be used in the present invention. However, the amount of chemical

additive necessary can be reduced due to the dearomatization of the naphtha

feed.

[0049] EXAMPLES:

[0050] A naphtha steam cracker according to the process configuration of

Fig. 1 was modeled using open specification naphtha (hereinafter OSN or grade

^■ - naphtha) as the feed for an ethylene plant having a capacity of 800 kTA

(thousand metric tons per annum), at a severity corresponding to propylene to

ethylene ratio of 0.5. Yields for OSN feed and the recycle streams were

calculated using the Pycos model. In comparing the grade naphtha feed to off-

grade feed streams, the naphtha steam cracker was modeled to first calculate

overall material balance, and then to calculate total furnace effluents, which

were used to characterize the size of major equipment for the ethylene plant.

The calculations are compared against current equipment size requirements and

capacities for existing ethylene plants to determine suitability of dearomatized

and non-dearomatized off-grade naphtha.

[0051] Two off grade naphthas (hereinafter naphtha A and naphtha B)

were selected to model the performance of a dearomatized off-grade naphtha

feed. The composition of the off-grade naphtha feeds are shown in Table 1

below:

Table 1 - Composition of Modeled Naphthas

OSN Naphtha Naphtha Naphtha A Naphtha B

Naphtha A B with DA with DA

Wt% Wt% Wt% Wt% Wt%

Normal Paraffins 31.9 25.0 20.0 32.9 26. 7

Iso Paraffins 34.4 30.0 21.0 39.5 28.0

Naphthenes 24.3 21.0 34.0 27.6 45.3

Aromatics 9.4 24.0 25.0 0.0 0.0

Total 100.0 100.0 100.0 100.0 100.0

Specific gravity 0.70 0.72 0.74 0.69 0.70

Total Paraffins 66.3 55.0 41.0 72.4 54.7

Paraffins+Naphthenes 90.6 76.0 75.0 100.0 100.0

As previously described, naphthas A and B are designated as off-grade because

they do not meet the OSN minimum paraffins specifications and therefore are

typically not used as steam cracker feeds. Table 1 also provides the

compositions of dearomatized naphtha A and B streams.

[0052] By removing the aromatic compounds from the naphtha A feed, the

paraffinic content can be increased to approximately 72% by weight, an

increase in the paraffins content of approximately 31% over the non-

dearomatized naphtha A feed. The dearomatized naphtha A feed meets the

OSN specification and making the feed suitable for steam cracker feed. The

paraffin content of the dearomatized naphtha B feed, having a paraffin content

of approximately 55% by weight (an increase of approximately 34%), is still

below 65% by weight, and would be rejected as a steam cracker feed.

[0053] EXAMPLE 1: In this example OSN based ethylene plant

performance with OSN naphtha is compared to steam cracker performance with

the naphtha A feed. The comparison shows that naphtha A is not well suited for

processing in the OSN based steam cracker. Yields were calculated using the

Pycos model. The naphtha A feed steam cracker performance is modeled to

first calculate overall material balance, and then total furnace effluents are

calculated to determine the size requirements for ethylene plant equipment.

Comparisons of overall material balance, the major area sizes and fouling

compounds in the quench oil tower feed of an OSN ethylene plant versus

Naphtha A based ethylene plant are presented in Table 2.

[0054] Table 2 shows that a naphtha A feedstream, being paraffin poor

and aromatics rich, produces approximately 79% more fuel oil than is produced

by an OSN naphtha feed. The equipment size factor is greatest for the fuel oil

stripper, meaning that the ethylene capacity for an OSN ethylene plant would be

reduced by approximately 50% when supplied with a naphtha A feedstream,

due to volume restrictions for the fuel oil stripper. Total capacity for a naphtha

A feed ethylene plant is approximately 400 kTA (i.e. 50% of the ethylene

capacity of the OSN ethylene plant).

[0055] EXAMPLE 2: An OSN feed ethylene plant is compared to a

dearomatized naphtha A feed ethylene plantusing the similar calculations as

used in Example 1. Table 3 shows comparisons of the overall material balance,

the major equipment sizes, and fouling compounds in the quench oil tower feed

for selected compounds in the furnace effluents.

[0056] As shown in Table 3, a dearomatized naphtha A feed, having had

aromatics removed, produces approximately 65% of the fuel oil produced from

an OSN naphtha feed. Similarly, the fuel oil stripper no longer limits the

ethylene capacity of the plant. The largest equipment size factor for

dearomatized naphtha A feed ethylene plant is 1.03 for the ethylene compressor,

which implies that the naphtha feed plant will produce approximately 97% of

the ethylene capacity of an OSN naphtha feed ethylene plant.

[0057] The styrene and fUel oil content of the quench oil tower feed is

indicative of quench oil tower fouling. In the case of a dearomatized naphtha A

feedstream, styrene and fuel oil production is approximately 60% of that for an

OSN feed, indicating that quench oil tower fouling should be substantially

reduced when dearomatized naphtha A is supplied as the feed.

[0058] One consequence of dearomatizing the naphtha A feedstream is

that on an overall basis, production of benzene and C8 aromatics can be

maximized. A comparison of the overall material balances for benzene and C8

aromatics is shown below. On a fixed ethylene production basis, benzene

production is 221 kTA for dearomatized naphtha A versus only 191 kTA for

non-dearomatized naphtha A. Similarly C8 aromatics production on a fixed

ethylene production basis is 296 kTA for dearomatized naphtha B versus 206

kTA for non-dearomatized naphtha B. On a fixed feed basis, benzene

production for dearomatized naphtha A is 9% greater than for non-dearomatized

naphtha A and C8 production for dearomatized naphtha A is 36% greater than

for non-dearomatized naphtha A.

Fixed Fixed Naphtha A % Increase Ethylene feed with DA

Naphtha A Naphtha A

Naphtha Feed (kTA) 2850.5 3022.2 3022.2

Benzene (kTA) 190.9 202.3 221.3 9

C8 Aromatics (kTA) 205.6 218.0 295.7 36

[0059] EXAMPLE 3 : In this example an OSN based steam cracker feed is

compared to a naphtha B based steam cracker feed showing the performance

and unsuitablity of naphtha B as a feed in an OSN based steam cracker. Yields

for naphtha B feed and the recycle streams were calculated using the Pycos

model. The naphtha B steam cracker is modeled to calculate overall material

balance, and total furnace effluents, which are used to determine the size of

major equipment for the ethylene plant. Table 4 shows a comparison of the

overall material balance, the major equipment sizes, and fouling compounds in

the quench oil tower feed for an OSN feed ethylene plant versus naphtha B feed

based ethylene plant.

[0060] Table 4 shows that naphtha B, being paraffin poor and aromatics

rich, produces more than twice the amount of fuel oil as compared with an OSN

feed. The area size factor for the fuel oil stripper is 2.2, which implies that an

OSN ethylene plant with a naphtha B feed will produce at 46% of the ethylene

capacity of an OSN feed plant.

[0061] EXAMPLE 4: In this example an OSN feed ethylene plant is

compared with a dearomatized naphtha B ethylene plant feed using the same

calculations. Table 5 shows the comparisons of overall material balance, the

major equipment sizes, and fouling compounds in the quench oil tower feed for

an OSN feed ethylene plant versus a dearomatized naphtha B feed ethylene

plant.

[0062] Table 5 shows that a dearomatized naphtha B feed, having no

aromatics, produces 80% of the fuel oil produced by the OSN feed. Similarly,

the fuel oil stripper is no longer a limiting factor to ethylene capacity. The

largest equipment size factor for a dearomatized naphtha B feed is 1.07 for the

number of coils. Based upon this limitation, production for the dearomatized

naphtha B feed is approximately 93% of the ethylene capacity of an OSN feed

ethylene plant. Capacity for a dearomatized naphtha B feed is approximately

twice that for the non-dearomatized naphtha B feed.

[0063] As previously noted, styrene and fuel oil content of quench oil

tower feed can be indicative of quench oil tower fouling. For a dearomatized

naphtha B feed, styrene and fuel oil production is approximately 85% of that for

an OSN feed, indicating that quench oil tower fouling should be reduced with a

dearomatized naphtha B feed.

[0064] On an overall basis, production of benzene and C8 aromatics is

maximized when the dearomatized naphtha is used. Comparison of the naphtha

B feed and dearomatized naphtha B feeds show that on fixed ethylene

production basis, benzene production is 283.6 kTA for dearomatized naphtha B

versus only 189.6 kTA for naphtha B. Similarly, C8 aromatics production on a

fixed ethylene production is 342.9 kTA for dearomatized naphtha B versus

219.1 kTA for naphtha B. On a fixed feed basis, benzene production is

increased with a dearomatized naphtha B feed to 284 kTA from 214 kTA, an

increase of 33%. Similarly, C8 aromatics production is increased to 343 kTA

from 247 kTA, an increase of 39% over an OSN feed. The calculations are

shown below:

Fixed Fixed Naphtha B % Increase

Ethylene Feed with DA

Naphtha B Naphtha B

Naphtha feed (IcTA) 2903.7 3273 .5 3273.5 Benzene QsJA) 189.6 213 .7 283.6 33 C8 Aromatics QsTA) 219.1 247 .0 342.9 39

[0065] EXAMPLE 5: An ethylene plant using the hybrid naphtha feed

system presented in the Figure 3 is shown here. The ethylene plant can be

supplied with an 80% feed of grade OSN naphtha and a 20% feed of off grade

naphtha A prepared using the dearomatization process of the present invention.

Table 6 shows the comparisons of overall material balance, the major

equipment sizes, and fouling compound compositions in the quench oil tower

feed of an OSN feed versus a dearomatized naphtha B feed ethylene plant.

[0066] As shown in Table 6, all of the equipment size factors for the

hybrid 80/20 case differ by less than 1%, indicating an ethylene production

capacity using the hybrid naphtha feed of approximately 99%, as compared to

the OSN feed ethylene plant production. A shortage of grade quality naphtha

feedstock meeting OSN specifications can be mitigated using off grade naphtha

by employing this invention. Levels of styrene and fuel oil in the quench oil

tower for the hybrid naphtha feed can be reduced by approximately 8%, as

compared to the OSN naphtha feed.

[0067] EXAMPLE 6: The benefits of a dearomatized naphtha feed for the

production at a propylene to ethylene ratio of 0.45 is shown in Table 7, where

comparisons of overall material balance, the major equipment sizes, and fouling

compounds in the quench oil tower feed for an OSN feed ethylene plant and a

dearomatized heavy naphtha A feed ethylene plant are given. Dearomatized

naphtha A, having no aromatic compounds present, produces approximately

63% of the fuel oil produced by OSN feed, and the fuel oil stripper is no longer

a limiting factor to ethylene capacity. The largest area size factor for a

dearomatized naphtha A feed is 1.03 for the ethylene compressor,

corresponding to an ethylene production capacity of approximately 97%, as

compared to capacity of an OSN naphtha feed.

[0068] Styrene and fuel oil content of the quench oil tower feed can be a

good indicator of fouling. For a dearomatized naphtha A feed, styrene and fuel

oil production can be reduced to approximately 66% of that of OSN feed

ethylene plant, indicating that quench oil tower fouling rates should be reduced

when using a dearomatized naphtha A feed stream as compared to an OSN feed

stream.

Heavy Naphtha Feed

[0069] To assess the suitability of dearomatized heavy naphtha we

selected two heavy naphthas, hereinafter heavy naphthas A and B, as shown in

the Table 8 below. As shown in Table 9, a naphtha steam cracker has been

modeled according to the process design configuration of Figure 5, using OSN

as the feed for an ethylene capacity of 800 kTA at a severity corresponding to a

propylene to ethylene ratio of 0.50. Yields for the OSN and the recycle streams

were calculated using the Pycos model. The naphtha steam cracker was

modeled to first calculate the overall material balance, and then to determine

total furnace effluents which can be used to characterize the size of major

equipment for the ethylene plant.

Table 8 - List of study naphthas

OSN Heavy Heavy Heavy Heavy Naphtha Naphtha Naphtha Naphtha Naphtha B

DA

Wt% Wt% Wt% Wt% Wt%

Normal Paraffins 31.9 25.0 20.0 32.9 26.7

Iso Paraffins 34.4 30.0 21.0 39.5 28.0

Naphthenes 24.3 21.0 34.0 27.6 45.3

Aromatics 9.4 24.0 25.0 0.0 0.0

Total 100.0 100.0 100.0 100.0 100.0

Specific gravity 0.70 0.74 0.76 0.71 0.73

Total Paraffins 66.3 55.0 41.0 72.4 54.7

Paraffins+Naphthenes 90.6 76.0 75.0 100.0 100.0

[0070] Note that heavy naphthas A and B have low paraffin contents and

therefore would normally be rejected as steam cracker feeds. Table 8 shows the

paraffin and aromatics compositions of dearomatized heavy naphtha A and B

feeds. By removing aromatics from heavy naphtha A, the paraffinic content can

be increased to approximately 72% by weight, an increase of approximately

31% over the non-dearomatized heavy naphtha A paraffmic content, which

would be acceptable for use as a steam cracker feed. The dearomatized heavy

naphtha B paraffinic content is approximately 55%, an increase of

approximately 34% over the non-dearomatized heavy naphtha B paraffinic

content, but still below acceptable levels. Therefore, dearomatized heavy

naphtha B would likely be rejected as a steam cracker feed.

[0071] EXAMPLE 7: In this example, grade naphtha steam cracker

performance is compared to heavy naphtha A based steam cracker performance

to demonstrate the lack of suitability of a heavy naphtha A feedstream for

ethylene production. Yields were calculated using the Pycos model. The heavy

naphtha A feed steam cracker is modeled to first calculate the overall material

balance, and then total furnace effluents are used to determine the size of major

equipment for the ethylene plant. Table 9 shows the comparisons of overall

material balance, the major equipment sizes and fouling compounds in the

quench oil tower feed of an OSN ethylene plant versus heavy naphtha A based

ethylene plant.

[0072] Table 9 shows that heavy naphtha A, paraffin poor and aromatics

rich, produces approximately 96% more fuel oil than an OSN feedstream. The

equipment size factor for the fuel oil stripper is the largest, meaning that to

process heavy naphtha A, the ethylene capacity of an OSN ethylene plant would

be reduced by approximately 50%, due to the reduced capacity of the fuel oil

stripper. Thus, the heavy naphtha A feedstream can produce approximately 400

kTA ethylene when using a heavy naphtha A feedstock in an OSN ethylene

plant.

[0073] EXAMPLE 8: An OSN naphtha feedstream ethylene plant is

compared with a dearomatized heavy naphtha A feedstream ethylene plant.

Table 10 shows a comparison of the overall material balance, the major

equipment sizes, fouling compounds present in the quench oil tower feed, and

selected products from the furnace effluents of ethylene plant for the OSN

naphtha feed plant versus a dearomatized heavy naphtha A feedstream, ethylene

plant.

[0074] Table 10 shows that the dearomatized heavy naphtha A feedstream,

having no aromatics present, produces only 60% of the fuel oil produced by a

grade naphtha feedstream ethylene plant. The fuel oil stripper is no longer a

limiting factor to the ethylene plant capacity. The largest equipment size factor

for using dearomatized heavy naphtha A feedstream is 1.03 for the ethylene

compressor, implying that the dearomatized heavy naphtha A feedstream

ethylene plant will produce approximately 97% of the ethylene capacity

obtainable with an OSN naphtha feedstream. In addition, a dearomatized

naphtha A feedstream can produce more than twice the ethylene able to be

produced with a non-dearomatized naphtha feedstream.

[0075] Styrene and fuel oil content of the quench oil tower feed can be

indicative of the likelihood quench oil tower fouling. For a dearomatized heavy

naphtha A feedstream, styrene and fuel oil production is approximately 60% of

that of an OSN naphtha feed, indicating that quench oil tower fouling should be

reduced when a dearomatized heavy naphtha A feedstream is steam cracked in

the ethylene plant.

[0076] One result of dearomatizing the heavy naphtha feedstream is that

on an overall basis, production of benzene and C8 aromatics can be maximized.

A comparison of the overall material balances from Tables 9 and 10 shows that

on a fixed ethylene production basis, benzene production is approximately 221

kTA for dearomatized heavy naphtha A, versus approximately 191 kTA for

naphtha A. Similarly, C8 aromatics production for the fixed ethylene

production case is 296 kTA for the dearomatized heavy naphtha A feed versus

206 kTA for naphtha A feed. On a fixed feed basis, benzene production for the

dearomatized heavy naphtha A is 221 kTA versus 202 kTZ for the non-

dearomatized heavy naphtha A, an increase of approximately 9%. Similarly, C8

aromatics production for dearomatized heavy naphtha A is 296 kTA, compared

with 218 kTA for the heavy naphtha A, an increase of approximately 36%.

Fixed Fixed DA % Increase

Ethylene Feed Heavy

Heavy Heavy Naphtha A

Naphtha A Naphtha A

Naphtha feed (kTA) 2850 3021 3021 Benzene (kTA) 191 202 221 9

C8 Aromatics (kTA) 206 218 296 36

Thus, with a fixed feed, steam cracking of dearomatized heavy naphtha A

shows an increase in both benzene and C8 aromatics production compared to

the steam cracking of heavy naphtha A.

[0077] EXAMPLE 9: In this example, an OSN feedstream based ethylene

plant is compared to a heavy naphtha B feed to show the suitability of the heavy

naphtha B feedstream for processing. Yields for heavy naphtha B feed and the

recycle streams were calculated using the Pycos model. The heavy naphtha B

steam cracker is modeled to first calculate overall material balances, and then

total furnace effluents are used to calculate the size of major equipment for the

ethylene plant. The Table 11 provides comparisons of overall material

balances, the major equipment sizes, and fouling compounds present in the

quench oil tower feed of an OSN naphtha ethylene plant versus the heavy

naphtha B based ethylene plant.

[0078] Table 11 provides a comparison showing that heavy naphtha B

feed, being paraffin poor and aromatics rich, can produces more than twice the

amount fuel oil as is produced by a grade naphtha process. The equipment size

factor for the fuel oil stripper is 2.16 and implies that heavy naphtha B feed

ethylene plant will produce approximately 46% of ethylene capacity compared

to an OSN naphtha feed.

[0079] EXAMPLE 10: An OSN naphtha feed ethylene plant is compared

to a dearomatized heavy naphtha B feed. Table 12 presents the comparisons of

overall material balances, the major equipment sizes, and fouling compounds

present in the quench oil tower feed for the OSN naphtha ethylene plant versus

the dearomatized heavy naphtha B feed ethylene plant.

[0080] Table 12 shows that dearomatized heavy naphtha B ₅ having no

aromatics present, produces approximately 80% of the fuel oil produced by an

OSN naphtha feed, meaning the fuel oil stripper is no longer a limiting factor to

ethylene capacity. The largest equipment size factor for the dearomatized heavy

naphtha B feed is 1.05 for the GHU feed, which implies that the ethylene plant

will be able to produce at approximately 95% of ethylene capacity with a

dearomatized heavy naphtha B feed, as compared to approximately 46% using

non-dearomatized heavy naphtha B feed.

[0081] Styrene and fuel oil production is approximately 85% of that of for

a grade naphtha feed, indicating that quench oil tower fouling should be reduced

for a dearomatized heavy naphtha B feedstream.

[0082] A comparison of Tables 11 and 12 shows that on fixed ethylene

production basis, benzene production is 283 kTA for dearomatized heavy

naphtha B feedstream versus 190 kTA for a naphtha B feedstream. Similarly,

C8 aromatics production for a fixed ethylene production is 343 kTA for

dearomatized heavy naphtha B feedstream versus 219 kTA for heavy naphtha B

feedstrean. On a fixed feed basis, benzene production for the dearomatized

heavy naphtha B is 283 kTA, compared with 214 kTA for the heavy naphtha B

feed, an increase of approximately 33%. Similarly, C8 aromatics production for

the dearomatized heavy naphtha B is 343 kTA, compared with 247 kTA for the

heavy naphtha B, an increase of approximately 39%.

Fixed Fixed Heavy % Increase

Ethylene Feed Naphtha B Heavy Heavy with DA

Naphtha B Naphtha B

Naphtha feed (kTA) 2902 3272 3272

Benzene (kTA) 190 214 283 33

C8 Aromatics (kTA) 219 247 343 39

[0083] EXAMPLE 11: A mixed feed system utilizing a hybrid feed

comprising 80% OSN naphtha and 20% dearomatized heavy naphtha A, as

shown in Figure 13, is provided here. Table 13 shows a comparison of overall

material balances, the major equipment sizes, and fouling compounds present in

the quench oil tower feed for an OSN naphtha feed ethylene plant versus a

dearomatized heavy naphtha B feed ethylene plant. A comparison of the

equipment sizes is given in Table 13 and shows that for all of the equipment

size factors for the mixed 80/20 case differ by less than 1%, indicating that in

using the hybrid feed an ethylene capacity of approximately 99% can be

obtained, compared to the OSN naphtha feedstock.

[0084] By using the mixed grade and dearomatized heavy naphtha feed, a

shortage of quality grade naphtha can be mitigated without a decrease in

ethylene production. Concentration of styrene and fuel oil in the quench oil

tower feed can be decreased by approximately 8%, which can reduce quench oil

tower fouling.

[0085] EXAMPLE 12: Table 14 shows the advantages for dearomatizing

the heavy naphtha A feedstream for the production of ethylene at a

propylene:ethylene ratio of 0.45. Table 14 shows comparisons of overall

material balance, the major equipment sizes, and fouling compounds present in

the quench oil tower feed feed of grade naphtha feed ethylene plant versus a

dearomatized heavy naphtha A feed ethylene plant operating at a P/E ratio of

0.45.

[0086] Table 14 comparison shows that dearomatized heavy naphtha A,

having no aromatics present, produces approximately 63% of the fuel oil

produced from an OSN naphtha feedstock, and that the fuel oil stripper is no

longer a limiting factor to the ethylene capacity. The largest equipment size

factor for the dearomatized heavy Naphtha A feed is 1.03 for the ethylene

compressor, implying that the ethylene plant will be able to operate at 97%

ethylene capacity using dearomatized heavy naphtha A feed as compared to

using OSN naphtha feedstock.

[0087] For a dearomatized heavy naphtha A feed, of the present example,

styrene and fuel oil production can be approximately 63% of that of the OSN

naphtha feed, indicating that quench oil tower fouling should be reduced when

dearomatized heavy naphtha A is used in the cracking process instead of the

grade naphtha.

[0088] Numerous embodiments and alternatives thereof have been

disclosed. While the above disclosure includes the best mode belief in carrying

out the invention as contemplated by the inventors, not all possible alternatives

have been disclosed. For that reason, the scope and limitation of the present

invention is not to be restricted to the above disclosure, but is instead to be

defined and construed by the appended claims.