Method for treating condensate feedstock

Abstract

The condensate feedstock may be treated by a method comprising passing the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light fraction stream and a heavy fraction stream. The method may further comprise decomposing the light fraction stream in a light fraction FCC reactor to form a first FCC effluent and decomposing the heavy fraction stream in a heavy fraction FCC reactor to form a second FCC effluent. The light fraction FCC reactor may be operated under harsher decomposition conditions than the heavy fraction FCC reactor.

Description

Technology Field

[0001] Cross-reference regarding related applications

[0002] This application claims interest in U.S. application serial number 18 / 634,148 filed April 12, 2024, and provisional application for India serial number 202331084039 filed December 9, 2023, the full disclosure of which is incorporated herein by reference. Background Technology

[0003] Technology field

[0004] The embodiments of the present disclosure generally relate to processes and systems used for chemical treatment, and more particularly, for converting condensate feedstocks into other chemicals.

[0005] background

[0006] Chemicals, such as light olefins and fuels, are typically produced by the thermal cracking of ethane, propane, butane, and naphtha. For example, ethylene produced by thermal cracking constitutes about 50% of total ethylene production. However, with the rising demand for these basic intermediate compounds, alternative production feedstocks are being considered compared to traditional thermal cracking and / or steam cracking processes using the available feedstocks listed above.

[0007] substance

[0008] Globally, the production of condensate has gradually increased over the past few decades. However, high amounts of naphthalene and aromatic content in condensate feedstocks typically amplify coke formation and contaminants, particularly in steam crackers. This is one of the limitations on process condensate directly in steam crackers. However, the present embodiment produces chemicals and fuels by fluid catalytic cracking ("FCC") using condensate, for example, those having an API specific gravity range of 45–55 degrees. The present embodiment enables the use of condensate feedstocks that yield relatively high amounts of chemicals and fuels. In particular, it has been found that condensate conversion can be enhanced by separating the condensate feedstock into at least two process streams and applying the lighter stream to harsher FCC conditions than the heavier stream.

[0009] According to one or more embodiments, the condensate feedstock may be processed by a method comprising passing the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light fraction stream and a heavy fraction stream. The light fraction stream may have a maximum boiling point approximately equal to the minimum boiling point of the heavy fraction stream. The light fraction stream may have a maximum boiling point of 230°C to 380°C, and the heavy fraction stream may have a minimum boiling point of 230°C to 380°C. At least 90 wt.% of the condensate feedstock may be included in the combination of the light fraction stream and the heavy fraction stream. The method may further comprise decomposing the light fraction stream in a light fraction FCC reactor to form a first FCC effluent and decomposing the heavy fraction stream in a heavy fraction FCC reactor to form a second FCC effluent. The light fraction FCC reactor may be operated under harsher decomposition conditions than the heavy fraction FCC reactor. The method may additionally include passing the first FCC effluent and the second FCC effluent through a second separation unit to form multiple downstream separated streams.

[0010] According to one or more additional embodiments, the condensate feedstock may be processed by a method comprising passing the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light fraction stream, an intermediate fraction stream, and a heavy fraction stream. The light fraction stream may have a maximum boiling point approximately equal to the minimum boiling point of the intermediate fraction stream, and the intermediate fraction stream may have a maximum boiling point approximately equal to the minimum boiling point of the heavy fraction stream. The light fraction stream may have a maximum boiling point of 150°C to 200°C, and the intermediate fraction stream may have a minimum boiling point of 150°C to 200°C. The intermediate fraction stream may have a maximum boiling point of 230°C to 380°C, and the heavy fraction stream may have a minimum boiling point of 230°C to 380°C. At least 90 wt.% of the condensate feedstock may be included in the combination of the light fraction stream, the intermediate fraction stream, and the heavy fraction stream. The method may further include decomposing a light fraction stream in a light fraction FCC reactor to form a first FCC effluent and decomposing a heavy fraction stream in a heavy fraction FCC reactor to form a second FCC effluent. The light fraction FCC reactor may be operated under harsher decomposition conditions than the light fraction FCC reactor. The method may further include passing the first FCC effluent and the second FCC effluent to a second separation unit to form a plurality of downstream separated streams.

[0011] These and other embodiments are described in more detail in the detailed description. It should be understood that both the general description above and the detailed description below are intended to present embodiments of the technology that are the subject of the invention and to provide an overview or framework for understanding the nature and features of the claimed technology. The accompanying drawings are included to provide further understanding of the technology disclosed herein and are incorporated into and constitute part of this specification. The drawings are provided to illustrate various embodiments and, together with the description, to explain the principles and operation of the technology described herein. Additionally, the drawings and description are meant to be illustrative only and are not intended to limit the claims in any way. Brief explanation of the drawing

[0012] Brief explanation of the drawing The following detailed description of specific embodiments of the present disclosure is best understood when read together with the following drawings, wherein similar structures indicate similar reference numbers, and where: FIG. 1 schematically illustrates a diagram of a condensate treatment system according to one or more embodiments described in the present disclosure; FIG. 2 schematically illustrates a diagram of another condensate treatment system according to one or more embodiments described in the present disclosure; FIG. 3 schematically illustrates a diagram of another condensate treatment system according to one or more embodiments described in the present disclosure. From now on, various embodiments will be performed with further reference to them, some of which are illustrated in the accompanying drawings. Where possible, the same reference numerals will be used to refer to identical or similar parts in the drawings. For the purpose of describing simplified schematic diagrams and related drawings, a number of valves, temperature sensors, electronic controllers, etc., which may be available to or are well known to those skilled in the art of specific chemical processing operations, are not included. Additionally, concomitant elements often included in typical chemical processing operations, e.g., air supply, catalyst hopper, and flue gas handling systems, are not illustrated. Concomitant elements present in the hydrocracking unit, e.g., bleed stream, spent catalyst discharge subsystem, and catalyst replacement subsystem, are also not shown. It should be understood that these elements are within the spirit and scope of the embodiments described herein. However, operating elements, e.g. those described in this disclosure, may be added to the embodiments described herein. Additionally, it should be noted that arrows in the drawings refer to process streams. However, arrows may equally refer to transfer lines that serve to move process streams between two or more system elements. Additionally, arrows connecting system elements define an inlet or outlet at each provided system element. The direction of the arrow generally corresponds to the primary direction of movement of the material of the stream contained within the physical transfer line indicated by the arrow. Additionally, arrows that do not connect two or more system elements indicate product streams exiting the illustrated system and / or system inlet streams entering the illustrated system. Product streams may be further processed in an accompanying chemical processing system or commercialized as final products. System inlet streams may be streams transferred from the accompanying chemical processing system or untreated feedstock streams. Some arrows may indicate recycle streams, which are effluent streams of system elements that are recycled back into the system. However, it should be understood that any indicated recycle stream may, in some embodiments, be replaced by a system inlet stream of the same material, and that a portion of the recycle stream may exit the system as a system product. Additionally, arrows in the drawings schematically illustrate process steps for transporting streams from one system element to another. For example, an arrow designating one system element to another may indicate "passing" system element effluent into the other system element, which may include the contents of a process stream "going out" or "removing" from one system element and the contents of a product stream "introducing" into the other system element. It should be understood that arrows in the relevant drawings do not indicate essential or fundamental steps. It should be understood that, depending on the embodiment, the relevant drawings are provided, and an arrow between two system elements may indicate that the stream is not processed between the two system elements. In other embodiments, the stream indicated by the arrow may have substantially the same composition during its transport between the two system elements. Additionally, it should be understood that in one or more embodiments, the arrow may indicate that at least 75 wt.%, at least 90 wt.%, at least 95 wt.%, at least 99 wt.%, at least 99.9 wt.%, or even 100 wt.% of the stream is transported between the system elements. As such, in some embodiments, not all streams indicated by the arrow may be transported between the system elements, for example, where a slip stream is present. It should be understood that if two or more lines intersect in the schematic flow diagram of the relevant drawings, two or more process streams are "mixed" or "blended." Mixing or blending may also involve mixing by directly introducing both streams into a similar reactor, separation unit, or other system element. For example, if two streams are depicted as being combined directly before entering a separation unit or reactor, it should be understood that in some embodiments, the streams are equally introduced into the separation unit or reactor and may be mixed in the reactor. Specific details for implementing the invention

[0013] details

[0014] The embodiments of the present disclosure relate to methods for processing condensate feedstocks. Generally, and as discussed herein, a condensate conversion system receives a condensate feedstock and produces chemicals and / or transport fuels. The embodiments of FIGS. 1-3 are each similar or identical in many ways, but include differences from those described herein. The description of the embodiments of FIGS. 1, 2, and 3 may generally be applicable to embodiments of the other figures as will be understood by a person skilled in the art. For example, concepts disclosed herein applicable to FIG. 1 may be equally applicable to FIG. 3, even if not explicitly stated herein, or vice versa.

[0015] Generally, in the embodiments described herein, the lighter portion of the condensate feedstock is subjected to harsher FCC conditions than the heavier portion of the condensate feedstock. It has been found that in this arrangement, a lower desired yield, e.g., fuel gas, can be produced compared to a higher desired yield, e.g., catalytically cracked naphtha and light olefins.

[0016] As used in this disclosure, the term “reactor,” e.g., the FCC reactor described herein, refers to a vessel in which one or more chemical reactions may occur between one or more reactants in the presence of optionally one or more catalysts. For example, the reactor may include a tank or tubular reactor, a gas phase reactor, a continuous stirred-tank reactor (CSTR), or a plug flow reactor. An example reactor includes a fluidized bed reactor. The reactor described herein may include a series of separated reactors. Additionally, the reactor may include separation devices, e.g., those for separating the catalyst from the reaction products. Such a reactor may also include a catalyst regeneration section, which is understood by those skilled in the art.

[0017] As used in this disclosure, “catalyst” refers to any substance that increases the rate of a specific chemical reaction. By using the catalysts described in this disclosure, various reactions, such as decomposition reactions, may be promoted, but are not limited thereto. As used in this disclosure, “decomposition catalysts” increase the rate of decomposition reactions. Such catalysts may have dual functionality. In some embodiments. The methods described herein are not necessarily limited to specific catalyst materials unless explicitly stated otherwise. As described herein, catalysts used for decomposition may be placed and fluidized, and gaseous reactants may be utilized. However, other arrangements are considered.

[0018] As used in this disclosure, the term “separation unit” refers to any separation device or system of separation devices that separates one or more chemicals mixed in a process stream at least partially from one another. For example, a separation unit may selectively separate substances of different chemical species, phases, or sizes that form one or more chemical fractions from one another. Examples of separation units include, but are not limited to, distillation columns, flash drums, knock-out drums, knock-out ports, centrifuges, cyclones, filtration devices, traps, scrubbers, expansion devices, membranes, solvent extraction devices, etc. It should be understood that the separation process described in this disclosure may not completely separate every one chemical component from every other chemical component. It should be understood that the separation process described in this disclosure separates different chemical elements “at least partially” from one another, and even, unless explicitly stated, the separation may include only partial separation.

[0019] In one or more embodiments, the condensate feedstock may be the primary or sole feedstock used to form the chemical product. As described herein, “condensate feedstock” generally refers to a hydrocarbon liquid that is condensed and formed when gas is extracted from an underground gas storage facility, as understood by those skilled in the art. Such condensate feedstock may have chemical species as light as C3 hydrocarbons and may have a final boiling point of at least 550°C, for example, between 550°C and 650°C. In some embodiments, 2 wt.% or less of the condensate feedstock may have a boiling point greater than 565°C. Such condensate feedstock may be produced from the Jafurah gas region of Saudi Arabia, referred herein as “Jafurah condensate.” Typical examples of Jafurah condensate feedstock compositions are provided in Table 1.

[0020]

[0021] According to some embodiments, the condensate feedstock described herein may have an API specific gravity of 45 to 55 degrees. For example, the condensate feedstock described herein may have an API specific gravity of 45 to 46 degrees, 46 to 47 degrees, 47 to 48 degrees, 48 ​​to 49 degrees, 49 to 50 degrees, 50 to 51 degrees, 51 to 52 degrees, 52 to 53 degrees, 53 to 54 degrees, 54 to 55 degrees, or any combination of one or more of these ranges.

[0022] Now, with reference to FIG. 1, a condensate treatment system (101) is illustrated. The condensate treatment system (101) may include at least one first separation unit (120), a heavy fraction FCC reactor (140), a light fraction FCC reactor (130), and a second separation unit (150). These system elements will be described in detail herein.

[0023] According to one or more embodiments, the condensate feedstock may be passed to the first separation unit (120). The condensate feedstock (108) may consist of the condensate feedstock. In some embodiments, the condensate feedstock may be processed in a de-salter (110), where at least some of the salt may be removed from the condensate feedstock before passing it to the first separation unit (120). It should be understood that some embodiments may not include a de-salter (110), and the condensate feedstock (108) may be passed directly to the first separation unit (120). In embodiments including a de-salter (110), the condensate feedstock may be passed through the condensate feedstock (112) after being de-salted in the de-salter (110) to the first separation unit (120). According to additional embodiments not shown in FIG. 1, the condensate feedstock may be further treated to remove other impurities, such as, but not limited to, alkali metals, nitrogen, and sulfur. Such treatment may remove impurities from the feedstock by hydrogenation of the condensate feedstock or by using a single or multiple protective layer.

[0024] Also with reference to FIG. 1, according to an embodiment, the condensate feedstock may be separated into at least two streams by a first separation unit (120). The first separation unit (120) may be any suitable separation unit, for example, but not limited to a scintillation vessel or a fractionator / distillation column that separates the feedstock based on the boiling point at a specified cut point. As described herein, in separation, the “cut point” generally identifies the approximate final boiling point of the lighter fraction and the approximate initial boiling point of the heavier fraction based on atmospheric pressure conditions. In some embodiments, for example, as shown in FIG. 1, the condensate feedstock stream (112) is separated into only two streams, a light fraction stream (122) and a heavy fraction stream (124). If other streams are generated by the first separation unit (120) (in addition to the light fraction stream (122) and the heavy fraction stream (124)), these streams may be only a relatively small portion of the condensate feed stream (112). For example, at least 90 wt.%, at least 95 wt.%, at least 99 wt.%, at least 99.9 wt.%, or 100 wt.% of the condensate feed stream (112) may be included in the combination of the light fraction stream (122) and the heavy fraction stream (124).

[0025] According to an embodiment, the cutoff point between the light fraction stream (122) and the heavy fraction stream (124) may exist within the range of 230°C to 380°C. In this embodiment, the light fraction stream (122) may have a maximum boiling point of 230°C to 380°C, and the heavy fraction stream (124) may have a minimum boiling point of 230°C to 380°C. According to some embodiments, the cutoff point between the light fraction stream (122) and the heavy fraction stream (124) may exist within the range of 230°C to 260°C. In this embodiment, the light fraction stream (122) may have a maximum boiling point of 230°C to 260°C, and the heavy fraction stream (124) may have a minimum boiling point of 230°C to 260°C. According to some other embodiments, the cutoff point between the light fraction stream (122) and the heavy fraction stream (124) may be within the range of 350°C to 380°C. In these embodiments, the light fraction stream (122) may have a maximum boiling point of 350°C to 380°C, and the heavy fraction stream (124) may have a minimum boiling point of 350°C to 380°C.

[0026] As illustrated in FIG. 1, the light fraction stream (122) and the heavy fraction stream (124) can be passed to the light fraction FCC reactor (130) and the heavy fraction FCC reactor (140), respectively. The decomposition of the light fraction stream (122) in the light fraction FCC reactor (130) can form the first FCC effluent (132), and the decomposition of the heavy fraction stream (124) in the heavy fraction FCC reactor (140) can form the second FCC effluent (142). As used in this disclosure, “cracking” may generally refer to a chemical reaction, wherein a molecule having a carbon-to-carbon bond is broken down into one or more molecules by breaking one or more carbon-to-carbon bonds, or a compound containing a cyclic moiety, e.g., cycloalkanes, cycloalkanes, naphthalenes, aromatics, etc., is converted into a compound that does not contain a cyclic moiety or contains fewer cyclic moietyes than before the cracking. The cracking may also involve the reduction of an alkene bond (i.e., the conversion of an alkene bond into an alkane bond). As is well understood by those skilled in the art, FCC is an abbreviation for fluid catalytic cracking, which generally refers to the use of fluidizing catalytic particles in contact with a gaseous feed. It is considered that a wide variety of catalysts may be used in the light fraction FCC reactor (130) and the heavy fraction FCC reactor (140), respectively. For example, a zeolite catalyst may be suitable.

[0027] As described herein, generally, a light fraction FCC reactor (130) may be operated under harsher decomposition conditions than a heavy fraction FCC reactor (140) (sometimes also referred to as a heavy fraction FCC reactor (140) operating under milder operating conditions than a light fraction FCC reactor (130)). Generally, harsher decomposition conditions are defined herein as conditions that promote decomposition in a reactor unit. As described herein, one reaction condition is harsher than another if more decomposition is observed when each reactor processes the same feedstock hydrocarbon. Variables that may affect the harshness of decomposition conditions include reactor temperature, residence time, catalyst composition, and catalyst-to-feed ratio. For example, higher temperatures, larger catalyst-to-feed ratios, and longer residence times generally correspond to harsher decomposition conditions. In some embodiments, the use of a riser may correspond to an additional residence time compared to a downer, as described in detail herein. Additionally, more catalytically active catalysts promote decomposition better and cause more severe decomposition reaction conditions.

[0028] As described, the light fraction FCC reactor (130) is operated under harsher decomposition conditions than the heavy fraction FCC reactor (140). In some embodiments, the light fraction FCC reactor (130) is operated at a higher temperature than the heavy fraction FCC reactor (140). For example, the light fraction FCC reactor (130) may be operated at a temperature at least 5°C higher than the heavy fraction FCC reactor (140), at least 10°C higher, at least 20°C higher, at least 30°C higher, at least 40°C higher, or even at least 50°C higher. In some embodiments, the light fraction FCC reactor (130) may be operated at a temperature of 600°C to 700°C, and the heavy fraction FCC reactor (140) may be operated at a temperature of 550°C to 650°C. For example, the light fraction FCC reactor (130) can be operated at a temperature of 600°C to 625°C, 625°C to 650°C, or 650°C to 675°C or 675°C to 700°C. Additionally, the heavy fraction FCC reactor (140) can be operated at a temperature of 550°C to 575°C, 575°C to 600°C, 600°C to 625°C, or 625°C to 650°C.

[0029] According to some embodiments, the catalyst-to-feed ratio of the light fraction FCC reactor (130) may be greater than that of the heavy fraction FCC reactor (140). The catalyst-to-feed ratio describes the relative amount of catalyst to the amount of hydrocarbon feed, e.g., the light fraction stream (122) or the heavy fraction stream (124), in each of the light fraction FCC reactor (130) and the heavy fraction FCC reactor (140). A larger catalyst-to-feed ratio may result in harsher decomposition conditions. In some embodiments, the catalyst-to-feed ratio of the light fraction FCC reactor (130) may be at least 1 greater, at least 2 greater, at least 4 greater, at least 6 greater, at least 8 greater, or even at least 10 greater than the catalyst-to-feed ratio of the heavy fraction FCC reactor (140). The catalyst-to-feed ratio is described in weight / weight terms unless otherwise stated herein. In some embodiments, the catalyst-to-feed ratio in a light fraction FCC reactor (130) may be 5 to 40 by weight. In some embodiments, the catalyst-to-feed ratio in a heavy fraction FCC reactor (140) may be 5 to 20 by weight.

[0030] According to some embodiments, the residence time of the light fraction FCC reactor (130) may be longer than the residence time of the heavy fraction FCC reactor (140) (e.g., 1 to 10 times). Generally speaking, the residence time refers to the average time that the catalyst interacts with the light fraction stream (122) or the heavy fraction stream (124) in the light fraction FCC reactor (130) or the heavy fraction FCC reactor (140), respectively. According to embodiments, the residence time of the light fraction FCC reactor (130) may be at least 0.1 s greater than the residence time of the heavy fraction FCC reactor (140), at least 0.2 s greater than the residence time of the heavy fraction FCC reactor (140), at least 0.3 s greater than the residence time of the heavy fraction FCC reactor (140), at least 0.4 s greater than the residence time of the light fraction FCC reactor (130), or even at least 0.5 s greater than the residence time of the heavy fraction FCC reactor (140).

[0031] In some embodiments, generally, a longer residence time may be provided when a riser reactor is used as a light fraction FCC reactor (130) and / or a heavy fraction FCC reactor (140) compared to when a downer reactor is used as a light fraction FCC reactor (130) and / or a heavy fraction FCC reactor (140). The selection of a riser or downer for the light fraction FCC reactor (130) and the heavy fraction FCC reactor (140) may be one way to affect the different residence times between the light fraction FCC reactor (130) and the heavy fraction FCC reactor (140). For example, generally, a longer residence time in the light fraction FCC reactor (130) compared to the heavy fraction FCC reactor (140) can be realized by selecting a riser for the light fraction FCC reactor (130) and a downer for the heavy fraction FCC reactor (140). Alternatively, at least both the light fraction FCC reactor (130) and the heavy fraction FCC reactor (140) may be a riser or a downer, respectively. However, in additional embodiments, a selection of a downer as the light fraction FCC reactor (130) and a riser as the heavy fraction FCC reactor (140) may be used, wherein reactor parameters are selected so that the light fraction FCC reactor (130) operates under harsher reaction conditions than the heavy fraction FCC reactor (140).

[0032] In additional embodiments, the catalyst composition used in the light fraction FCC reactor (130) may be more catalytically active than in the heavy fraction FCC reactor (140). For example, the catalyst used may be a zeolite catalyst, for example, a catalyst comprising ZSM-5 zeolite. In some embodiments, ZSM-5 may be mesoporous, which means that ZSM-5 has an average pore size of 2 nm to 100 nm (compared to conventional ZSM-5 zeolite which has only a microstructure and an average pore size of less than 2 nm). In some embodiments, harsher decomposition conditions may be presented in the light fraction FCC reactor (130) than in the heavy fraction FCC reactor (140) by using a larger amount of mesoporous ZSM-5 zeolite in the light fraction FCC reactor (130) than in the heavy fraction FCC reactor (140).

[0033] After the decomposition of the light fraction stream (122) and the heavy fraction stream (124), which results in the formation of the first FCC effluent (132) and the second FCC effluent (142), the first FCC effluent (132) and the second FCC effluent (142) may be passed to a second separation unit (150). The first FCC effluent (132) and the second FCC effluent (142) may be passed to the second separation unit (150) separately, as shown in FIG. 1, or may be combined and sent together to the second separation unit (150). The second separation unit (150) may be a distillation column / fractionator and, depending on some embodiments, may be as shown in FIG. 1. However, a series of separation devices may be used as recognized by a person skilled in the art. Various downstream separated streams may be formed by the separation of the first FCC effluent (132) and the second FCC effluent (142). For example, in some embodiments, the effluent (downstream separated stream) of the second separation unit (150) may include fuel gas (172), a stream (178) containing liquefied petroleum gas (LPG) together with C3-C4 light olefins, catalytically cracked naphtha (154), light cycle oil (156), and heavy cycle oil (158). These downstream separated streams may sometimes have variable compositions, but generally, the fuel gas (172) contains H2 and C1-C2 types, the stream (178) contains liquefied petroleum gas containing C3-C4 paraffins along with C3-C4 light olefins, the catalytically cracked naphtha (154) contains C5 hydrocarbons with boiling points of about 220°C or lower (e.g., boiling points in the range of 210°C to 230°C), and the light cycle oil (156) contains hydrocarbons with boiling points of about 220°C (e.g., within the range of 210°C to 230°C) to about 350°C (e.g., within the range of 340°C to 360°C).Heavy cycle oil (158) may contain hydrocarbons with a boiling point greater than about 350°C (e.g., within the range of 340°C to 360°C).

[0034] Also, with reference to FIG. 1, in some embodiments, the fuel gas (172) and stream (178) may exit the second separation unit (150) as stream (152) and be separated into their respective streams. The fuel gas (172) may be used as a product stream, or, for example, in the condensate treatment system (101) as fuel for heating the light fraction stream (122) and / or heavy fraction stream (124). The catalytically cracked naphtha (154) may be passed to a saturation unit (170). The saturation unit (170) may be operated to saturate the diolefins in the catalytically cracked naphtha (154) and improve the olefin content to improve the yield in the mixed feed steam cracker unit (160). The saturated unit (170) may be a typical naphtha / gasoline hydrogenator operating with a CoMo hydrogenation catalyst at a pressure of 25-45 barg at 200-320°C. The saturated unit effluent (168) may exit the saturated unit (170).

[0035] In one or more embodiments, both stream (178) (present after separation of C3-C4 light olefins) and saturated unit effluent (168) may be passed to a mixed feed steam cracker unit (160) to form stream cracked effluent (162). That is, in some embodiments, stream (178) may be separated into a stream containing C3-C4 light olefins that may be passed to an olefin separation unit (not shown in FIG. 1), and a stream containing C3-C4 paraffins that may be passed to a mixed feed steam cracker unit (160). The mixed feed steam cracker unit (160) may be a combination of different thermal (pyrolysis) steam cracking furnaces capable of processing feeds, e.g., ethane, propane, butane, as well as liquids, e.g., naphtha (low or no olefin content) and gas oil (boiling point from 180°C to 365°C). Typically, each furnace is custom-made (coil material of structure, batch and residence time) to decompose materials with a narrow boiling point range. In a mixed feed steam decomposition unit (160), multiple decomposition furnaces can be operated to process different fractions in parallel. Products from each furnace can be combined and processed in a downstream olefin separation section that can be integrated with a catalytic decomposition downstream section. The pyrolysis furnace can be operated at an outlet temperature of 700°C to 900°C and an inlet pressure of 1.5 barg or more.

[0036] Also, with reference to FIG. 1, light cycle oil (156) may be passed to a diesel production unit (180) capable of forming diesel (182). The diesel production unit (180) may be a typical diesel hydroprocessing unit or a mild hydrocracker. In some embodiments, the diesel production unit (180) may be an LCO (light cycle oil) hydroprocessing / mild hydrocracker unit operated for the purpose of producing a substance that can be sold as diesel or blended with other diesel elements. A typical unit may operate at 350-420°C and a pressure of 50-100 barg. Various available mild hydrocracker catalysts (CoMo or NiMo catalysts) may be used.

[0037] The heavy cycle oil (158) may exit the condensate treatment system (101) as a product (174) as fuel oil, which may be used as fuel for the thermal balance requirements of a catalytic cracker or sold elsewhere. In some embodiments, part (or all) of the heavy cycle oil (158) may be recycled in the condensate treatment system (101). In particular, as shown in FIG. 1, the heavy cycle oil (176) may be mixed with the heavy fraction stream (124) or passed directly to the heavy fraction FCC reactor (140).

[0038] Now, with reference to FIG. 2, another condensate processing system (102) is illustrated. The condensate processing system (102) may be similar or identical to the condensate processing system (101) of FIG. 1, except where otherwise described. In particular, the condensate processing system (102) may utilize different processing of stream (178) and catalytically cracked naphtha (154). According to some embodiments, stream (178) (containing liquefied petroleum gas along with C3-C4 light olefins) may be passed to an olefin separation unit (190), whereby the stream (178) is separated into olefins (194) and non-olefins (196). Additionally, the catalytically cracked naphtha (154) may be passed to a gasoline production unit (192) that produces gasoline (198). The gasoline production unit (192) may be a gasoline hydroprocessor similar to the naphtha production unit. The goal of such units may be to produce a substance that can meet gasoline specifications or can be blended with other suitable substances to meet gasoline specifications.

[0039] Now, with reference to FIG. 3, another condensate processing system (103) is illustrated. The condensate processing system (103) may be similar or identical to the condensate processing system (101) of FIG. 1, except where otherwise described. In particular, the condensate processing system (103) may utilize a different separation reaction equation in the first separation unit (120). According to one or more embodiments, the first separation unit (120) may separate the condensate feed stream (112) into at least one light fraction stream (122), a medium fraction stream (126), and a heavy fraction stream (124). Generally, the light fraction stream (122) may have a lighter element than the medium fraction stream (126), and the medium fraction stream (126) may have a lighter element than the heavy fraction stream (124). In some embodiments, for example, as illustrated in FIG. 3, the condensate feed stream (112) is separated into only three streams: a light fraction stream (122), an intermediate fraction stream (126), and a heavy fraction stream (124). If other streams are generated by the first separation unit (120) (in addition to the light fraction stream (122), the intermediate fraction stream (126), and the heavy fraction stream (124)), these streams may be only a relatively small portion of the condensate feed stream (112). For example, at least 90 wt.%, at least 95 wt.%, at least 99 wt.%, at least 99.9 wt.%, or 100 wt.% of the condensate feed stream (112) may be included in a combination of the light fraction stream (122), the intermediate fraction stream (126), and the heavy fraction stream (124).

[0040] According to an embodiment, the cutoff point between the light fraction stream (122) and the medium fraction stream (126) may exist within the range of 150°C to 200°C. In this embodiment, the light fraction stream (122) may have a maximum boiling point of 150°C to 200°C, and the medium fraction stream (126) may have a minimum boiling point of 150°C to 200°C. The cutoff point between the medium fraction stream (126) and the heavy fraction stream (124) may exist within the range of 230°C to 380°C. In this embodiment, the medium fraction stream (126) may have a maximum boiling point of 230°C to 380°C, and the heavy fraction stream (124) may have a minimum boiling point of 230°C to 380°C. According to some embodiments, the cutoff point between the intermediate fraction stream (126) and the heavy fraction stream (124) may exist within the range of 230°C to 260°C. In this embodiment, the intermediate fraction stream (126) may have a maximum boiling point of 230°C to 260°C, and the heavy fraction stream (124) may have a minimum boiling point of 230°C to 260°C. According to some other embodiments, the cutoff point between the intermediate fraction stream (126) and the heavy fraction stream (124) may exist within the range of 350°C to 380°C. In this embodiment, the intermediate fraction stream (126) may have a maximum boiling point of 350°C to 380°C, and the heavy fraction stream (124) may have a minimum boiling point of 350°C to 380°C.

[0041] Also, with reference to FIG. 3, the intermediate fraction stream (126) may be passed to a kerosene / diesel production unit (128). The kerosene / diesel production unit (128) may produce diesel or kerosene (134) based on the exact specifications of the intermediate fraction stream (126). The kerosene / diesel production unit (128) may operate similarly to the diesel production unit (180) described for FIG. 1. In a further embodiment, the intermediate fraction stream (126) may be combined with catalytically cracked naphtha (154), and the combined stream may be processed in a saturated unit (170).

[0042] Although not shown in the individual drawings, it is considered that the separation-post-reaction scheme of FIG. 2 (after the second separation unit (150)) can be used together with the 3-stream separation scheme of FIG. 3.

[0043] Several specific embodiments are described below. These embodiments may be combined with one another, and it should be understood that some aspects of a specific embodiment may be combined with aspects of different embodiments.

[0044] In a first embodiment, the condensate treatment system (101) of FIG. 1 may utilize a riser for a light fraction FCC reactor (130) and a riser for a heavy fraction FCC reactor (140). The first separation unit (120) may produce only two streams, a light fraction stream (122) and a heavy fraction stream (124), having a cutoff point of about 245°C (e.g., 230°C to 260°C). Approximately 40-80 wt.% of the condensate feed stream (112) may be processed in the light fraction FCC reactor (130). Conditions in the light fraction FCC reactor (130) include a reaction temperature of 600-675°C, a catalyst / feed ratio of 5-40 wt / wt, and a residence time of 2-3 sec. The catalyst mixture may each consist of (i) 10-75 wt.% modified USY (in the presence and absence of rare earth additives); and (ii) 90-25 wt.% mesoporous H-ZSM-5-based additives. The heavy fraction stream (124) may be approximately 20-60 wt.% condensate feed stream (112) and may be processed in a heavy fraction FCC reactor (140). Conditions in the heavy fraction FCC reactor (140) may include a temperature of 550-650°C, a catalyst / feed ratio of 5-20 wt / wt, and a residence time of 2-3 sec. The catalyst mixture may consist of (i) 20-80 wt.% USY (in the presence and absence of rare earth modified additives); and (ii) each may consist of 20-80 wt.% of a mesoporous H-ZSM-5 based additive.

[0045] The second embodiment is the same as the first embodiment, but uses a cutoff point between the light fraction stream (122) and the heavy fraction stream (124) of about 365°C (e.g., 350°C to 380°C).

[0046] The third embodiment is identical to the first embodiment, but uses the separation-post-reaction equation of the condensate treatment system (102) of FIG. 2.

[0047] The fourth embodiment is identical to the second embodiment, but uses the separation-post-reaction equation of the condensate treatment system (102) of FIG. 2.

[0048] A fifth embodiment is identical to a first embodiment, but uses a downer as a heavy fraction FCC reactor (140). Conditions in the heavy fraction FCC reactor (140) include a reaction temperature of 550-650°C, a catalyst / feed ratio of 5-20 wt / wt, and a residence time of 0.1-1 sec. The catalyst mixture may each consist of (i) 20-80 wt.% of modified USY (in the presence and absence of rare earth additives); and (ii) 20-80 wt.% of a mesoporous H-ZSM-5 based additive.

[0049] The 6th embodiment is the same as the 5th embodiment, but uses a cutoff point between the light fraction stream (122) and the heavy fraction stream (124) of about 365°C (e.g., 350°C to 380°C).

[0050] The seventh embodiment is identical to the first embodiment, but uses a downer for the light fraction FCC reactor (130) and a downer for the heavy fraction FCC reactor (140). Conditions in the light fraction FCC reactor (130) include a reaction temperature of 600-675°C, a catalyst / feed ratio of 5-40 wt / wt, and a residence time of 0.1-1 sec. The catalyst mixture may consist of (i) 10-75 wt.% modified USY (in the presence and absence of rare earth additives); and (ii) 90-25 wt.% mesoporous H-ZSM-5 based additives, respectively. The heavy fraction stream (124) may be approximately 20-60 wt.% condensate feed stream (112) and may be processed in the heavy fraction FCC reactor (140). Conditions in a heavy fraction FCC reactor (140) may include a temperature of 550–650°C, a catalyst / feed ratio of 5–20 wt / wt, and a residence time of 0.1–1 sec. The catalyst mixture may each consist of (i) 20–80 wt.% USY (in the presence and absence of rare-earth modified additives); and (ii) 20–80 wt.% mesoporous H-ZSM-5 based additives.

[0051] The 8th embodiment is the same as the 7th embodiment, but uses a cutoff point between the light fraction stream (122) and the heavy fraction stream (124) of about 365°C (e.g., 350°C to 380°C).

[0052] In the ninth embodiment, a condensate treatment system (103) is used, wherein the cutoff point between the light fraction stream (122) and the medium fraction stream (126) is about 185°C (e.g., 150°C to 200°C), and wherein the cutoff point between the medium fraction stream (126) and the heavy fraction stream (124) is about 245°C (e.g., 230°C to 260°C).

[0053] The 10th embodiment is the same as the 9th embodiment, but uses a cutoff point between the intermediate fraction stream (126) and the heavy fraction stream (124) at about 365°C (e.g., 350°C to 380°C).

[0054] Many aspects are incorporated into the present disclosure. One aspect is a method for treating a condensate feedstock, said method comprising: passing the condensate feedstock through a first separation unit and separating the condensate feedstock into at least a light fraction stream and a heavy fraction stream, wherein: the light fraction stream has a maximum boiling point approximately equal to the minimum boiling point of the heavy fraction stream; the light fraction stream has a maximum boiling point of 230°C to 380°C, and the heavy fraction stream has a minimum boiling point of 230°C to 380°C; and at least 90 wt.% of the condensate feedstock is included in the combination of the light fraction stream and the heavy fraction stream; and decomposing the light fraction stream in a light fraction FCC reactor to form a first FCC effluent. The step of decomposing a heavy fraction stream in a heavy fraction FCC reactor to form a second FCC effluent, wherein the light fraction FCC reactor operates under harsher decomposition conditions than the heavy fraction FCC reactor; and the step of passing the first FCC effluent and the second FCC effluent to a second separation unit to form a plurality of downstream separated streams.

[0055] Another aspect is any prior aspect or a combination of prior aspects, wherein, the condensate feedstock has an API specific gravity of 45 to 55 degrees; the condensate feedstock has a final boiling point of 550 to 650 degrees; or the condensate feedstock boils at 5 wt.% or less above 565 degrees.

[0056] Another aspect is any previous aspect or a combination of previous aspects, where: the light fraction stream has a maximum boiling point of 230°C to 260°C and the heavy fraction stream has a minimum boiling point of 230°C to 260°C; or the light fraction stream has a maximum boiling point of 350°C to 380°C and the heavy fraction stream has a minimum boiling point of 350°C to 380°C.

[0057] Another aspect is any prior aspect or a combination of prior aspects, and further comprises removing at least a portion of the salt from the condensate feed before passing the condensate feed through the first separation device.

[0058] Another aspect is any previous aspect or a combination of previous aspects, where the light fraction FCC reactor is operated at a higher temperature than the heavy fraction FCC reactor.

[0059] Another aspect is any previous aspect or a combination of previous aspects, where the light fraction FCC reactor operates with a larger catalyst-to-feed ratio than the heavy fraction FCC reactor.

[0060] Another aspect is any previous aspect or a combination of previous aspects, where the light fraction FCC reactor operates with a longer residence time than the heavy fraction FCC reactor.

[0061] Another aspect is any prior aspect or a combination of prior aspects, where: the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a riser; the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a downer; the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a downer; or the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a riser.

[0062] Another aspect is any prior aspect or a combination of prior aspects, wherein the entire condensate feedstock is included in the combination of the light fraction stream and the heavy fraction stream.

[0063] Another aspect is any previous aspect or a combination of previous aspects, wherein a larger amount of mesoporous zeolite is used in the light fraction FCC reactor than in the heavy fraction FCC reactor.

[0064] Another aspect is any prior aspect or a combination of prior aspects, wherein a plurality of downstream separated streams comprise at least: a fuel gas stream; a stream comprising C3-C4 paraffins and C3-C4 light olefins passed to a mixed feed steam cracker unit; a catalytically cracked naphtha stream passed to a saturated unit; a light cycle oil stream passed to a diesel production unit; and a heavy cycle oil stream.

[0065] Another aspect is any prior aspect or a combination of prior aspects, wherein a plurality of downstream separated streams comprises at least: a fuel gas stream; a stream containing C3-C4 paraffins and C3-C4 light olefins passed to an olefin separation unit; a catalytically cracked naphtha stream passed to a gasoline production unit; a light cycle oil stream passed to a diesel production unit; and a heavy cycle oil stream.

[0066] Another aspect is a method for treating a condensate feedstock, said method comprising: passing the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light fraction stream, an intermediate fraction stream, and a heavy fraction stream, wherein: the light fraction stream has a maximum boiling point approximately equal to the minimum boiling point of the intermediate fraction stream, and the intermediate fraction stream has a maximum boiling point approximately equal to the minimum boiling point of the heavy fraction stream; the light fraction stream has a maximum boiling point of 150°C to 200°C, and the intermediate fraction stream has a minimum boiling point of 150°C to 200°C; the intermediate fraction stream has a maximum boiling point of 230°C to 380°C, and the heavy fraction stream has a minimum boiling point of 230°C to 380°C; and at least 90 wt.% of the condensate feedstock is included in the combination of the light fraction stream, the intermediate fraction stream, and the heavy fraction stream. The method comprises the steps of: decomposing a light fraction stream in a light fraction FCC reactor to form a first FCC effluent; decomposing a heavy fraction stream in a heavy fraction FCC reactor to form a second FCC effluent, wherein the light fraction FCC reactor operates under harsher decomposition conditions than the light fraction FCC reactor; and passing the first FCC effluent and the second FCC effluent to a second separation unit to form a plurality of downstream separated streams.

[0067] Another aspect is any previous aspect or a combination of previous aspects, where the condensate feedstock has an API specific gravity of 45 to 55 degrees.

[0068] Another aspect is any previous aspect or a combination of previous aspects, where: the intermediate fraction stream has a maximum boiling point of 230°C to 260°C and the heavy fraction stream has a minimum boiling point of 230°C to 260°C; or the intermediate fraction stream has a maximum boiling point of 350°C to 380°C and the heavy fraction stream has a minimum boiling point of 350°C to 380°C.

[0069] Another aspect is any previous aspect or a combination of previous aspects, where the light fraction FCC reactor is operated at a higher temperature than the heavy fraction FCC reactor.

[0070] Another aspect is any previous aspect or a combination of previous aspects, where the light fraction FCC reactor operates with a larger catalyst-to-feed ratio than the heavy fraction FCC reactor.

[0071] Another aspect is any previous aspect or a combination of previous aspects, where the light fraction FCC reactor operates with a longer residence time than the heavy fraction FCC reactor.

[0072] Another aspect is any prior aspect or a combination of prior aspects, where: the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a riser; the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a downer; the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a downer; or the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a riser.

[0073] Another aspect is any prior aspect or a combination of prior aspects, wherein a plurality of downstream separated streams comprise at least: a fuel gas stream; a stream comprising C3-C4 paraffins and C3-C4 light olefins, wherein at least C3-C4 paraffins are passed to a mixed feed steam cracker unit; a catalytically cracked naphtha stream is passed to a saturated unit; a light cycle oil stream is passed to a diesel production unit; and a heavy cycle oil stream.

[0074] It should be noted that for the purpose of describing and defining the present disclosure, the terms “about” or “approximately” are used in the present disclosure to indicate the degree of inherent uncertainty that may be attributed to any quantitative comparison, value, measurement, or other expression. The terms “about” and / or “approximately” are also used in the present disclosure to indicate the extent to which a quantitative expression may vary from a stated standard without causing a change in the fundamental function of the subject matter at issue.

[0075] It should be noted that one or more of the following claims use "wherein" as a term transition phrase. It should be noted that for the purpose of defining the technology of the present invention, such term is introduced into the claims as an open-end transition phrase used to introduce a citation of a series of features of the structure, and should be interpreted in a manner similar to the more commonly used open-end introductory term "comprising."

[0076] Any quantitative value expressed in this application may be considered to include open-end embodiments corresponding to the transition phrase “comprising” or “including,” as well as closed or partially closed embodiments corresponding to the transition phrase “consisting of” and “consisting essentially of”.

[0077] It should also be noted that the citation of "at least one" component, element, etc. in this application should not be used to infer that the alternative use of an article (“a” or “an”) should be limited to a single component, element, etc.

Claims

Claim 1 A method for treating a condensate feedstock, wherein the method comprises the step of passing the condensate feedstock through a first separation unit and separating the condensate feedstock into at least a light fraction stream and a heavy fraction stream, wherein: The light fraction stream has a maximum boiling point approximately equal to the minimum boiling point of the heavy fraction stream; The light fraction stream has a maximum boiling point of 230°C to 380°C, and the heavy fraction stream has a minimum boiling point of 230°C to 380°C; A method comprising the steps of: at least 90 wt.% of the condensate feedstock being included in the combination of the light fraction stream and the heavy fraction stream; decomposing the light fraction stream in a light fraction FCC reactor to form a first FCC effluent; decomposing the heavy fraction stream in a heavy fraction FCC reactor to form a second FCC effluent, wherein the light fraction FCC reactor is operated under harsher decomposition conditions than the heavy fraction FCC reactor; and passing the first FCC effluent and the second FCC effluent to a second separation unit to form a plurality of downstream separated streams. Claim 2 A method according to claim 1, wherein the condensate feedstock has an API specific gravity of 45° to 55°C; the condensate feedstock has a final boiling point of 550°C to 650°C; or at least one of the following: 5 wt.% or less of the condensate feedstock boils at a temperature greater than 565°C. Claim 3 A method according to claim 1 or 2, wherein the light fraction stream has a maximum boiling point of 230°C to 260°C and the heavy fraction stream has a minimum boiling point of 230°C to 260°C; or the light fraction stream has a maximum boiling point of 350°C to 380°C and the heavy fraction stream has a minimum boiling point of 350°C to 380°C. Claim 4 A method according to any one of claims 1 to 3, wherein the light fraction FCC reactor is operated at a higher temperature than the heavy fraction FCC reactor. Claim 5 A method according to any one of claims 1 to 4, wherein the light fraction FCC reactor is operated with a greater catalyst-to-feed ratio than the heavy fraction FCC reactor. Claim 6 A method according to any one of claims 1 to 5, wherein the light fraction FCC reactor is operated with a longer residence time than the heavy fraction FCC reactor. Claim 7 A method according to any one of claims 1 to 6, wherein the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a riser; the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a downer; the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a downer; or the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a riser. Claim 8 A method according to any one of claims 1 to 7, wherein the entire condensate feedstock is included in the combination of the light fraction stream and the heavy fraction stream. Claim 9 A method for treating a condensate feedstock, wherein the method comprises: passing the condensate feedstock through a first separation unit and separating the condensate feedstock into at least a light fraction stream, an intermediate fraction stream, and a heavy fraction stream, wherein: The light fraction stream has a maximum boiling point approximately equal to the minimum boiling point of the medium fraction stream, and the medium fraction stream has a maximum boiling point approximately equal to the minimum boiling point of the heavy fraction stream; The light fraction stream has a maximum boiling point of 150°C to 200°C, and the intermediate fraction stream has a minimum boiling point of 150°C to 200°C; The above intermediate fraction stream has a maximum boiling point of 230°C to 380°C, and the above heavy fraction stream has a minimum boiling point of 230°C to 380°C; A method comprising: a step in which at least 90 wt.% of the condensate feedstock is included in a combination of the light fraction stream, the intermediate fraction stream, and the heavy fraction stream; a step of decomposing the light fraction stream in a light fraction FCC reactor to form a first FCC effluent; a step of decomposing the heavy fraction stream in a heavy fraction FCC reactor to form a second FCC effluent, wherein the light fraction FCC reactor operates under harsher decomposition conditions than the light fraction FCC reactor; and a step of passing the first FCC effluent and the second FCC effluent to a second separation unit to form a plurality of downstream separated streams. Claim 10 In claim 9, the method wherein the condensate feedstock has an API specific gravity of 45 to 55 degrees. Claim 11 The method of claim 9 or 10, wherein the intermediate fraction stream has a maximum boiling point of 230°C to 260°C and the heavy fraction stream has a minimum boiling point of 230°C to 260°C; or the intermediate fraction stream has a maximum boiling point of 350°C to 380°C and the heavy fraction stream has a minimum boiling point of 350°C to 380°C. Claim 12 A method according to any one of claims 9 to 11, wherein the light fraction FCC reactor is operated at a higher temperature than the heavy fraction FCC reactor. Claim 13 A method according to any one of claims 9 to 12, wherein the light fraction FCC reactor is operated with a greater catalyst-to-feed ratio than the heavy fraction FCC reactor. Claim 14 A method according to any one of claims 9 to 13, wherein the light fraction FCC reactor is operated with a longer residence time than the heavy fraction FCC reactor. Claim 15 A method according to any one of claims 9 to 14, wherein the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a riser; the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a downer; the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a downer; or the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a riser.

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