Condensate feedstock treatment process

Abstract

A method of processing a condensate feedstock can include: delivering the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light ends stream and a heavy ends stream. Another method of processing a condensate feedstock can include: delivering the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light ends stream, a middle distillate stream, and a heavy ends stream. Various downstream processing steps are further disclosed.

Description

Cross-reference to related applications

[0001] This application claims priority to U.S. Patent Application No. 18 / 632,698, filed April 11, 2024, and Indian Provisional Application No. 202331085308, filed December 14, 2023, the entire disclosure of which is incorporated herein by reference. Technical Field

[0002] The embodiments disclosed herein relate generally to the field of chemical processing, and more specifically to methods and systems for converting condensate feedstocks into other chemicals. Background Technology

[0003] Chemicals such as light olefins and fuels are typically produced via thermal cracking processes using ethane, propane, butane, and naphtha. For example, thermal cracking accounts for approximately 50% of total ethylene production. However, with the increasing demand for these basic intermediates, alternative production methods beyond the conventional thermal cracking and / or steam cracking processes utilizing the aforementioned feedstocks have been considered. Summary of the Invention

[0004] Over the past few decades, global condensate production has continued to grow. However, the high content of cycloalkanes and aromatics in condensate feedstocks often exacerbates coke formation and fouling, especially in steam cracking units. This is one of the limiting factors for directly processing condensates in steam cracking units. This paper presents an embodiment that utilizes condensates with an API strength in the range of 45 to 55 degrees Celsius to produce chemicals and fuels via fluidized bed catalytic cracking (FCC). This embodiment enables high-yield production of chemicals and fuels using condensate feedstocks. Specifically, the study found that condensate conversion can be improved by separating the condensate feedstock into at least two process streams and processing only the heavier stream via FCC, while allowing the lighter stream to bypass FCC processing and be used for other downstream processing (e.g., in gasoline production units or steam cracking units).

[0005] According to one or more embodiments, a method for processing condensate feedstock may include: feeding the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light distillate stream and a heavy distillate stream. The maximum boiling point of the light distillate stream may be approximately equal to the minimum boiling point of the heavy distillate stream. The maximum boiling point of the light distillate stream may be between 170°C and 260°C, and the minimum boiling point of the heavy distillate stream may be between 170°C and 260°C. At least 90% by weight of the condensate feedstock may be included in the combination of the light distillate stream and the heavy distillate stream. The method may further include: cracking the heavy distillate stream in an FCC reactor to form an FCC effluent; feeding the FCC effluent to a second separation unit to form a catalytically cracked naphtha stream; and feeding the catalytically cracked naphtha stream and the light distillate stream to a gasoline preparation unit or a mixed feed steam cracking unit.

[0006] According to one or more other embodiments, a method for processing condensate feedstock may include: feeding the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light distillate stream, a middle distillate stream, and a heavy distillate stream. The maximum boiling point of the light distillate stream may be approximately equal to the minimum boiling point of the middle distillate stream, and the maximum boiling point of the middle distillate stream may be approximately equal to the minimum boiling point of the heavy distillate stream. The maximum boiling point of the light distillate stream may be between 170°C and 200°C, and the minimum boiling point of the middle distillate stream may be between 170°C and 200°C. The maximum boiling point of the middle distillate stream may be between 230°C and 380°C, and the minimum boiling point of the heavy distillate stream may be between 230°C and 380°C. At least 90% by weight of the condensate feedstock may be included in a combination of the light distillate stream, the middle distillate stream, and the heavy distillate stream. The method may further include: cracking the heavy fraction stream in an FCC reactor to form an FCC effluent; sending the FCC effluent to a second separation unit to form a catalytically cracked naphtha stream; sending the catalytically cracked naphtha stream and the light fraction stream to a catalytic reforming unit to form a reforming effluent; and sending the reforming effluent and the middle fraction stream to a gasoline production unit.

[0007] These and other embodiments will be described in more detail in the specific embodiments. It should be understood that the foregoing general description and the following specific embodiments embody embodiments of the present disclosure and are intended to provide an overview or framework for understanding the nature and features of the claimed technology. The included drawings are intended to provide a further understanding of the present disclosure and are incorporated into and form part of this specification. The drawings illustrate various embodiments and, together with the specification, explain the principles and operation of the present disclosure. Furthermore, the drawings and description are intended to be illustrative only and do not limit the scope of the claims in any way. Attached Figure Description

[0008] The following detailed description of specific embodiments of this disclosure will be more readily understood in conjunction with the accompanying drawings, wherein the same structures are indicated by the same reference numerals: Figure 1 A schematic diagram of a condensate treatment system according to one or more embodiments of the present disclosure is depicted. Figure 2 A schematic diagram of another condensate treatment system according to one or more embodiments of the present disclosure is depicted. Figure 3 A schematic diagram of another condensate treatment system according to one or more embodiments of the present disclosure is depicted; and Figure 4 A schematic diagram of yet another condensate treatment system according to one or more embodiments of the present disclosure is depicted.

[0009] The various embodiments will now be described in more detail, some of which are shown in the accompanying drawings. Where possible, the same reference numerals are used to refer to the same or similar components.

[0010] To facilitate the simplified illustration and description of the accompanying drawings, various valves, temperature sensors, electronic controllers, and other equipment that are used in certain chemical processing operations and are well-known to those skilled in the art are not included herein. Furthermore, common auxiliary components in typical chemical processing operations (such as air supply systems, catalyst hoppers, and flue gas treatment systems) are also not shown in the drawings. Ancillary components within the hydrocracking unit, such as exhaust pipelines, spent catalyst discharge subsystems, and catalyst replacement subsystems, are also not shown. It should be understood that these components are all within the spirit and scope of the embodiments of this disclosure. However, the embodiments described in this disclosure may further include operating components such as those described herein.

[0011] It should be further clarified that the arrows in the diagram represent process streams. However, these arrows can also be used interchangeably to refer to conveyor lines used to transport process streams between two or more system components. Furthermore, arrows connecting system components indicate the inlet or outlet of a given system component; the arrow direction is generally consistent with the primary direction of material flow within the physical conveyor line. Further, arrows not connecting two or more system components represent product streams output from the system or system inlet streams entering the system. Product streams can be further processed in an associated chemical processing system or sold as end products; system inlet streams can be streams from an associated chemical processing system or untreated raw material streams. Some arrows may represent recirculated streams, which are effluent streams from system components that are recycled back into the system. However, it should be understood that in some embodiments, any illustrated recirculated stream can be replaced with the system inlet stream of the same material, and a portion of the recirculated stream can leave the system as a system product.

[0012] Furthermore, the arrows in the figures can schematically represent process steps that transfer material from one system component to another. For example, an arrow pointing from one system component to another can indicate the "transfer" of the effluent from one system component to another, which includes "discharging" or "removing" the process material contents from one system component and "introducing" the contents of that product material into another system component. It should be understood that the arrows in the relevant figures do not represent mandatory or necessary steps.

[0013] It should be understood that, according to the embodiments shown in the relevant figures, the arrow between two system components may indicate that the logistics is unprocessed between the two system components. In other embodiments, the logistics represented by the arrow may have substantially the same composition throughout the transport between the two system components. Furthermore, it should be understood that in one or more embodiments, the arrow may indicate that at least 75% by weight, at least 90% by weight, at least 95% by weight, at least 99% by weight, at least 99.9% by weight, or even 100% by weight of the logistics transported between the system components. Thus, in some embodiments, less than the total logistics represented by the arrow may be transported between the system components, for example, if side-stream logistics are present.

[0014] It should be understood that when two or more pipelines intersect in the schematic flow diagram of the relevant figures, two or more process streams are "mixed" or "combined". Mixing or combining may also include mixing by directly introducing the two streams into similar reactors, separation units, or other system components. For example, it should be understood that when the two streams are described as being combined directly before entering a separation unit or reactor, in some embodiments, the streams may be equivalently introduced into the separation unit or reactor and mixed in the reactor.

[0015] The various embodiments will now be described in more detail, some of which are shown in the accompanying drawings. Where possible, the same reference numerals are used to refer to the same or similar components. Detailed Implementation

[0016] The embodiments disclosed herein relate to methods for processing condensate feedstocks. Generally, as discussed herein, the condensate conversion system receives condensate feedstocks and outputs chemicals and / or transport fuels. Figures 1 to 4 The implementation schemes are similar or identical in many respects, but differ as described herein. Those skilled in the art will understand that... Figures 1 to 4 The description of the embodiments herein is generally applicable to embodiments in other figures. For example, those applicable herein are... Figure 1 The concept can also be applied to Figure 2 , Figure 3 or Figure 4Conversely, the same applies, even if not explicitly stated in this article.

[0017] In general, in the embodiments described herein, the heavier fraction of the condensate feedstock is processed by the FCC, while one or more relatively lighter fractions bypass the FCC and are used for downstream fuel or chemical production. It has been found that, under this configuration, highly desired products, such as transportation fuels, aromatics, and / or light olefins, can be produced in higher yields compared to less desirable products.

[0018] As used herein, a “reactor” (e.g., an FCC reactor) refers to a vessel in which one or more reactants optionally undergo one or more chemical reactions in the presence of one or more catalysts. For example, a reactor may include a tank or tubular reactor, a gas-phase reactor, a continuous stirred tank reactor (CSTR), or a plug flow reactor. Example reactors include fluidized bed reactors. As described herein, a reactor may comprise a series of separate reactors. Furthermore, a reactor may include separation equipment, such as those for separating the catalyst from the reaction products. Those skilled in the art will also understand that such reactors may also include a catalyst regeneration section.

[0019] As used herein, "catalyst" means any substance that can increase the rate of a particular chemical reaction. The catalysts described herein can be used to promote a variety of reactions, such as, but not limited to, cracking reactions. As used herein, a "cracking catalyst" increases the rate of a cracking reaction. In some embodiments, such catalysts may have a dual function. The methods described herein are not necessarily limited to specific catalytic materials. As described herein, including those catalysts used for cracking, catalysts can be in a fluidized configuration and utilize gaseous reactants. However, other configurations are also contemplated.

[0020] As used in this disclosure, "separation unit" means any separation apparatus or system that at least partially separates one or more chemicals mixed in a process stream from each other. For example, a separation unit may selectively separate different chemicals, phases, or materials of different sizes from each other to form one or more chemical fractions. Examples of separation units include, but are not limited to, distillation columns, flash tanks, separators, centrifuges, cyclone separators, filtration devices, traps, scrubbers, expansion devices, membranes, solvent extraction equipment, etc. It should be understood that the separation processes described in this disclosure may not completely separate all one chemical component from all another chemical component. It should be understood that the separation processes described in this disclosure "at least partially" separate different chemical components from each other, and even if not explicitly stated, separation may include only partial separation.

[0021] In one or more embodiments, the condensate feedstock is the primary or sole feedstock for the preparation of the chemical product. As described herein, "condensate feedstock" generally refers to the hydrocarbon liquid that condenses and forms when natural gas is extracted primarily from underground gas reservoirs, as is well known to those skilled in the art. Such condensate feedstocks may contain a chemical composition of light to C3 hydrocarbons and have a final boiling point of at least 550°C, for example, 550°C to 650°C. In some embodiments, the portion of the condensate feedstock with a boiling point above 565°C may be less than or equal to 2% by weight. Such condensate feedstocks may be those produced from the Jafurah gas field in Saudi Arabia, referred to herein as "Jafurah condensate." Typical examples of the composition of Jafurah condensate feedstocks are shown in Table 1.

[0022] Table 1

[0023] According to some implementation schemes, the API degree of the condensate feedstock described herein may be between 45 and 55 degrees. For example, its API degree range may be 45 to 46, 46 to 47, 47 to 48, 48 to 49, 49 to 50, 50 to 51, 51 to 52, 52 to 53, 53 to 54, 54 to 55, or any combination of one or more of the above ranges.

[0024] See now Figure 1 The figure shows a condensate treatment system 101. This condensate treatment system 101 may include at least a first separation unit 120, an FCC reactor 130, and a second separation unit 150. These system components will be described in detail herein. According to one or more embodiments, the condensate feedstock can be conveyed to the first separation unit 120. The condensate feed stream 108 consists of this condensate feedstock. In some embodiments, the condensate feedstock can be treated in a desalter 110, which removes at least a portion of the salt from the condensate feedstock before it enters the first separation unit 120. It should be understood that some embodiments may not include the desalter 110, and the condensate feed stream 108 can be conveyed directly to the first separation unit 120. For embodiments including the desalter 110, the condensate feedstock desalted by the desalter 110 can be conveyed to the first separation unit 120 via the condensate feed stream 112. Figure 1 In other embodiments not shown, the condensate feedstock may be further processed to remove other impurities, such as, but not limited to, alkali metals, nitrogen, and sulfur. Such processing may be achieved by hydrogenation of the condensate feedstock or by using one or more guard beds to remove impurities.

[0025] Continue to refer to Figure 1According to the implementation scheme, the condensate feedstock can be separated into at least two streams via a first separation unit 120. The first separation unit 120 can be any suitable separation unit, such as, but not limited to, a flash tank or fractionating / distillation column that separates the feedstock based on boiling point at a specific cut-off point. As described herein, a "cut-off point" in separation generally refers to the approximate final boiling point of the lighter fraction and the approximate initial boiling point of the heavier fraction under atmospheric pressure. In some implementations, such as... Figure 1 As shown, the condensate feedstock stream 112 is separated into only two streams: a light fraction stream 122 and a heavy fraction stream 124. If the first separation unit 120 generates other streams (in addition to the light fraction stream 122 and the heavy fraction stream 124), these streams constitute only a small portion of the condensate feedstock stream 112. For example, at least 90% by weight, at least 95% by weight, at least 99% by weight, at least 99.9% by weight, or 100% by weight of the condensate feedstock stream 112 may be included in the combination of the light fraction stream 122 and the heavy fraction stream 124.

[0026] According to the implementation scheme, the cutoff point between the light distillate stream 122 and the heavy distillate stream 124 can be in the range of 170°C to 260°C. In this type of implementation, the maximum boiling point of the light distillate stream 122 can be between 170°C and 260°C, and the minimum boiling point of the heavy distillate stream 124 can be between 170°C and 260°C. Figure 1 As shown, the heavy distillate stream 124 can be fed to the FCC reactor 130. According to one or more embodiments, 50% to 70% by weight of the condensate feed stream 112 can be included in the heavy distillate stream 124. For example, 55% to 65% by weight of the condensate feed stream 112 can be included in the heavy distillate stream 124.

[0027] The heavy distillate stream 124 is cracked in FCC reactor 130 to form FCC effluent 132. As used in this disclosure, "cracking" generally refers to a chemical reaction in which molecules having carbon-carbon bonds are broken into multiple molecules by breaking one or more carbon-carbon bonds, or from a compound containing cyclic moieties (e.g., cycloalkanes, cycloolefins, naphthalenes, aromatics, etc.) to a compound that does not contain cyclic moieties or contains fewer cyclic moieties than before cracking. Cracking may also include the reduction of alkene bonds (i.e., the conversion of alkene bonds to alkane bonds). As is well known to those skilled in the art, FCC is an abbreviation for fluidized catalytic cracking, which generally refers to a reaction using fluidized catalytic particles in contact with a gaseous feed. It is foreseeable that a variety of catalysts can be used in FCC reactor 130. For example, zeolite catalysts are suitable. FCC reactor 130 can be operated as a riser or downpipe and should not be limited by specific process conditions such as temperature, pressure, residence time, catalyst composition and / or catalyst-to-feed ratio. However, according to some implementations, the FCC reactor 130 can be operated at a reactor temperature of 500°C to 700°C, the catalyst to feed ratio (by weight) in the FCC reactor 130 can be 1 to 50, and / or the residence time of the FCC reactor 130 can be 0.1 seconds to 10 seconds.

[0028] After cracking, the heavy distillate stream 124 forms FCC effluent 132, which can be sent to the second separation unit 150. According to some implementation schemes, such as... Figure 1 As shown, the second separation unit 150 can be a distillation column. However, those skilled in the art will recognize that a series of separation devices can also be used. Various downstream separation streams can be formed by separating the FCC effluent 132. For example, in some embodiments, the effluent of the second separation unit 150 (i.e., the downstream separation streams) may include fuel gas 172, a stream 178 containing liquefied petroleum gas (LPG) and C3-C4 light olefins, catalytically cracked naphtha 154, light cycle oil 156, and heavy cycle oil 158. While the composition of these downstream separated streams may vary, generally, fuel gas 172 contains H2 and C1-C2 hydrocarbons, stream 178 contains liquefied petroleum gas (containing C3-C4 alkanes and C3-C4 light olefins), catalytic cracked naphtha 154 contains C5 hydrocarbons to hydrocarbons with a boiling point of about 220°C (e.g., boiling point range of 210°C to 230°C), and light cycle oil 156 contains hydrocarbons with a boiling point of about 220°C (e.g., range of 210°C to 230°C) to about 350°C (e.g., range of 340°C to 360°C). Heavy cycle oil 158 may contain hydrocarbons with a boiling point above about 350°C (e.g., range of 340°C to 360°C).

[0029] Continue to refer to Figure 1In some embodiments, fuel gas 172 and stream 178 can be discharged from the second separation unit 150 as stream 152 and separated into their respective streams. Fuel gas 172 can be used as a product stream or as fuel in the condensate treatment system 101, for example, to balance the heat balance of the FCC reactor 130. Stream 172 can also be sent to downstream units, such as the olefin separation unit 190, where stream 172 is separated into olefins 194 and non-olefins 196.

[0030] According to some implementation schemes, stream 178 can be sent to olefin separation unit 190, where stream 178 is separated into olefins 194 and non-olefins 196.

[0031] Continue to refer to Figure 1 According to one or more embodiments, catalytically cracked naphtha 154 and light distillate stream 122 can be fed to gasoline preparation unit 192 to produce gasoline 198. For example... Figure 1 As shown, the light distillate stream 122 and the FCC effluent 132 can be combined and sent together to the gasoline preparation unit 192, or they can be sent to the gasoline preparation unit 192 as separate streams. The gasoline preparation unit 192 can be a gasoline hydrotreating processor, similar to a naphtha preparation unit. The goal of this unit can be to produce materials that meet gasoline specifications or can be blended with other suitable materials to meet gasoline specifications.

[0032] Unbound by any particular theory, it is believed that feeding the light fraction stream 122 to the gasoline production unit 192 (i.e., bypassing the FCC reactor 130) can increase the yield of fuel and other chemicals such as light olefins. It is believed that, in some embodiments, by referring to... Figure 1 The method described in the implementation plan can produce 30% to 50% by weight of fuels (such as gasoline and diesel) and 20% to 40% by weight of high-value chemicals such as light olefins (i.e., ethylene, propylene, butene) and / or aromatics (such as toluene, benzene and mixed xylenes) from the condensate feed stream.

[0033] Continue to refer to Figure 1 Light cycle oil 156 can be fed to diesel production unit 180 to form diesel 182. This diesel production unit 180 can be a typical diesel hydrotreating unit or a mild hydrocracking unit. In some embodiments, the diesel production unit 180 can be an LCO (light cycle oil) hydrotreating / mild hydrocracking unit, with the operational objective of producing a product that can be sold as diesel or blended with other diesel components. Typical units can operate at 350°C–420°C and 50 barg–100 barg pressures. A variety of suitable mild hydrocracking catalysts (CoMo or NiMo catalysts) can be used.

[0034] Continue to refer to Figure 1 The heavy-recycle oil 158 discharged from the second separation unit 150 can be discharged from the condensate treatment system 101 as fuel oil 174. Furthermore, the diesel fuel preparation unit 180 can produce fuel oil 184, which is discharged from the condensate treatment system 101, and as... Figure 1 As shown in the implementation plan, it can be combined with heavy cycle oil 158.

[0035] For reference Figure 2 It describes another condensate treatment system 102. This condensate treatment system 102 can be used with... Figure 1 The condensate treatment system 102 is similar to or the same as that described herein, unless otherwise stated. Specifically, as described herein, the condensate treatment system 102 can separate the condensate feed stream 112 into at least three fractions, and two lighter fractions can bypass the FCC reactor 130 and be sent to the gasoline preparation unit 192.

[0036] According to one or more implementation schemes, such as Figure 2 As shown, the first separation unit 120 can separate the condensate feed stream 112 into at least a light distillate stream 122, a middle distillate stream 126, and a heavy distillate stream 124. Typically, the light distillate stream 122 is lighter than the middle distillate stream 126, and the middle distillate stream 126 is lighter than the heavy distillate stream 124. If the first separation unit 120 also produces other streams (in addition to the light distillate stream 122, middle distillate stream 126, and heavy distillate stream 124), these streams may constitute only a small portion of the condensate feed stream 112. For example, at least 90% by weight, at least 95% by weight, at least 99% by weight, at least 99.9% by weight, or 100% by weight of the condensate feed stream 112 may be included in the combination of the light distillate stream 122, the middle distillate stream 126, and the heavy distillate stream 124.

[0037] According to the implementation scheme, the cutoff point between the light distillate stream 122 and the middle distillate stream 126 can be in the range of 170°C to 200°C. In this implementation scheme, the maximum boiling point of the light distillate stream 122 can be in the range of 170°C to 200°C, and the minimum boiling point of the middle distillate stream 126 can be in the range of 170°C to 200°C. The cutoff point between the middle distillate stream 126 and the heavy distillate stream 124 can be in the range of 205°C to 235°C. In this implementation scheme, the maximum boiling point of the middle distillate stream 126 can be in the range of 205°C to 235°C, and the minimum boiling point of the heavy distillate stream 124 can be in the range of 205°C to 235°C.

[0038] and Figure 1 The implementation scheme shown is similar, in Figure 2In this implementation scheme, the heavy distillate stream 124 is fed to the FCC reactor 130 to form FCC effluent 132, and the FCC effluent 132 is separated into at least fuel gas 172, liquefied petroleum gas (LPG), catalytic cracked naphtha 154, light cycle oil 156, and heavy cycle oil 158. The processing of the LPG downstream of the second separation unit 150 can be combined with... Figure 1 The processes described in the implementation plan are similar or identical.

[0039] According to one or more embodiments, catalytically cracked naphtha 154 and light distillate stream 122 are fed to a catalytic reforming unit 140. For example... Figure 2 As shown, the light distillate stream 122 and the catalytically cracked naphtha 154 can be combined and fed together to the catalytic reforming unit 140, or they can be fed to the catalytic reforming unit 140 as separate streams. The operation of the catalytic reforming unit 140 can be used to increase the octane number of hydrocarbons and form reformate effluent 142. Unrestrictedly, this reforming process can convert low-octane straight-chain hydrocarbons (alkanes) into branched-chain alkanes (isoalkanes) and cycloalkanes, which can then be partially dehydrogenated to produce high-octane aromatics.

[0040] Continue to refer to Figure 2 The reformate effluent 142 and the middle distillate stream 126 are fed to the gasoline preparation unit 192 to form gasoline 198. For example... Figure 2 As shown, the reformate effluent 142 and the middle distillate stream 126 can be combined and sent together to the gasoline preparation unit 192, or they can be sent to the gasoline preparation unit 192 as separate streams.

[0041] In some embodiments, the diesel production unit 180 may generate fuel oil 184, which may be fed as a recycle stream to the FCC reactor 130. Additionally, heavy recycle oil 158 may be fed as a recycle stream to the FCC reactor 130. In such embodiments, fuel oil 184 and heavy recycle oil 158 may be combined to form stream 159, which may be combined with heavy fraction stream 124 or fed separately to the FCC reactor 130.

[0042] Unbound by any particular theory, it is believed that feeding the light distillate stream 122 and the middle distillate stream 126 to the gasoline preparation unit 192 (i.e., bypassing the FCC reactor 130) can improve the yield of fuels and other chemicals such as light olefins. It is believed that, in some embodiments, by referring to... Figure 2 The method described in the implementation plan can produce 50% to 70% by weight of fuels (such as gasoline and diesel) and 20% to 30% by weight of high-value chemicals such as light olefins (i.e., ethylene, propylene, butene) and / or aromatics (such as toluene, benzene and mixed xylenes) from the condensate feed stream.

[0043] For reference Figure 3 It describes another condensate treatment system 103. This condensate treatment system 103 can be used with... Figure 1 The condensate handling system 101 and / or Figure 2 The condensate treatment system 103 is similar to or the same as that described herein, unless otherwise stated. Specifically, as described herein, the condensate treatment system 103 can separate the condensate feed stream 112 into at least three fractions (similar to...). Figure 2 Furthermore, the two lightest fractions can bypass the FCC reactor 130, with the light fraction stream 122 being fed to the mixed feed steam cracking unit 160, and the middle fraction stream 126 being fed to the kerosene preparation unit 186 to form kerosene 188.

[0044] According to one or more implementation schemes, such as Figure 3 As shown, the first separation unit 120 can separate the condensate feed stream 112 into at least a light distillate stream 122, a middle distillate stream 126, and a heavy distillate stream 124. Typically, the light distillate stream 122 is lighter than the middle distillate stream 126, and the middle distillate stream 126 is lighter than the heavy distillate stream 124. If the first separation unit 120 also produces other streams (in addition to the light distillate stream 122, middle distillate stream 126, and heavy distillate stream 124), these streams may constitute only a small portion of the condensate feed stream 112. For example, at least 90% by weight, at least 95% by weight, at least 99% by weight, at least 99.9% by weight, or 100% by weight of the condensate feed stream 112 may be included in the combination of the light distillate stream 122, the middle distillate stream 126, and the heavy distillate stream 124.

[0045] According to the implementation scheme, the cutoff point between the light distillate stream 122 and the middle distillate stream 126 can be in the range of 170°C to 200°C. In this implementation scheme, the maximum boiling point of the light distillate stream 122 can be in the range of 170°C to 200°C, and the minimum boiling point of the middle distillate stream 126 can be in the range of 170°C to 200°C. The cutoff point between the middle distillate stream 126 and the heavy distillate stream 124 can be in the range of 205°C to 235°C. In this implementation scheme, the maximum boiling point of the middle distillate stream 126 can be in the range of 205°C to 235°C, and the minimum boiling point of the heavy distillate stream 124 can be in the range of 205°C to 235°C.

[0046] and Figure 1 and Figure 2 The implementation scheme shown is similar, in Figure 3 In one embodiment, the heavy distillate stream 124 is fed to the FCC reactor 130 to form FCC effluent 132, and the FCC effluent 132 is separated into at least fuel gas 172, liquefied petroleum gas, catalytic cracked naphtha 154, light cycle oil 156 and heavy cycle oil 158.

[0047] According to the implementation scheme, catalytically cracked naphtha 154 can be fed to a saturation unit 170. This saturation unit 170 can be used to saturate the dienes in the catalytically cracked naphtha 154 and improve the olefin content to increase the yield of the mixed feed steam cracking unit 160. The saturation unit 170 can be a typical naphtha / gasoline hydrotreating processor, operating at 200°C to 270°C and pressures of 25 barg to 45 barg, using a cobalt-molybdenum (CoMo) hydrotreating catalyst. The saturation unit 170 can discharge saturation unit effluent 168.

[0048] Continue to refer to Figure 3 The saturated unit effluent 168 and the light distillate stream 122 can be fed to the mixed feed steam cracking unit 160. In some embodiments, such as Figure 3 As shown, the saturated unit effluent 168 and the light distillate stream 122 are combined before being fed to the mixed feed steam cracking unit 160. In other embodiments, the saturated unit effluent 168 and the light distillate stream 122 may be fed to the mixed feed steam cracking unit 160 separately. Furthermore, the liquefied petroleum gas may be fed to the mixed feed steam cracking unit 160 alone or in combination with other streams (such as the saturated unit effluent 168 and / or the light distillate stream 122).

[0049] Continue to refer to Figure 3 The heavy recycle oil 158 discharged from the second separation unit 150 can be discharged from the condensate treatment system 103 as fuel oil 174. In some embodiments, a portion of the heavy recycle oil 158 can be sent to the FCC reactor 130 as a recycle stream via stream 159. In some embodiments, stream 159 is combined with the heavy fraction stream 124, and the combined stream is sent to the FCC reactor 130.

[0050] The mixed-feed steam cracking unit 160 can be a combination of different thermal cracking (pyrolysis) steam cracking furnaces, capable of processing feedstocks such as ethane, propane, and butane, as well as liquids such as naphtha (low or no olefins) and gas oil (boiling point between 180°C and 365°C). Typically, each cracking furnace can be customized to meet process requirements (including coil material, configuration, and residence time) to crack materials with narrow boiling point ranges. Multiple cracking furnaces within the mixed-feed steam cracking unit 160 can operate in parallel, processing different fractions separately. Products from each cracking furnace can be collected and processed in a downstream olefin separation section, which can be integrated with the downstream section of catalytic cracking. The thermal cracking furnaces can operate at outlet temperatures of 700°C to 900°C and inlet pressures of 1.5 barg or higher. Cracking effluent 162 and / or a portion of liquefied petroleum gas can be fed to the olefin separation unit 190, where stream 178 is separated into olefins 194 and non-olefins 196.

[0051] Continue to refer to Figure 3 The middle distillate stream 126 and the light cycle oil 156 can be fed to the kerosene preparation unit 186 to form kerosene 188. The light cycle oil 156 and the middle distillate stream 126 can be fed to the kerosene preparation unit 186 separately, or they can be combined before entering the kerosene preparation unit 186.

[0052] Unbound by any particular theory, it is believed that feeding the light distillate stream 122 to the mixed feed steam cracking unit 160 and the middle distillate stream 126 to the kerosene preparation unit 186 (i.e., bypassing the FCC reactor 130) can improve the yield of fuels and other chemicals such as light olefins. It is believed that, in some embodiments, through… Figure 3 The method described in the implementation scheme can produce 40% to 60% by weight of fuels (such as gasoline and diesel) and 20% to 30% by weight of high-value chemicals such as light olefins (i.e., ethylene, propylene, butene) and / or aromatics (such as toluene, benzene and mixed xylenes) from the condensate feed stream.

[0053] For reference Figure 4 It describes another condensate treatment system 104. This condensate treatment system 104 can be used with... Figure 1 Condensate treatment system 101 Figure 2 The condensate treatment system 102 and / or Figure 3 The condensate treatment system 104 is similar to or the same as that described herein, unless otherwise stated. Specifically, as described herein, the condensate treatment system 104 can separate the condensate feed stream 112 into at least two fractions, and the lightest fraction can bypass the FCC reactor 130 and be delivered to the mixed feed steam cracking unit 160.

[0054] like Figure 4 As shown, according to the embodiment, the cutoff point between the light distillate stream 122 and the heavy distillate stream 124 can be in the range of 170°C to 260°C. In this embodiment, the maximum boiling point of the light distillate stream 122 can be in the range of 170°C to 260°C, and the minimum boiling point of the heavy distillate stream 124 can be in the range of 170°C to 260°C. In other embodiments, the cutoff point between the light distillate stream 122 and the heavy distillate stream 124 can be in the range of 170°C to 200°C, wherein the maximum boiling point of the light distillate stream 122 can be in the range of 170°C to 200°C, and the minimum boiling point of the heavy distillate stream 124 can be in the range of 170°C to 200°C. In other embodiments, the cut-off point between the light distillate stream 122 and the heavy distillate stream 124 may be in the range of 230°C to 260°C, wherein the maximum boiling point of the light distillate stream 122 may be in the range of 230°C to 260°C, and the minimum boiling point of the heavy distillate stream 124 may be in the range of 230°C to 260°C.

[0055] and Figure 3 Compared to the implementation scheme, the downstream processing of the second separation unit 150 can be similar or identical in many respects. That is, as... Figure 3 Similarly, the light distillate stream 122 is fed to the mixed feed steam cracking unit 160. Furthermore, the processing of liquefied petroleum gas is similar to... Figure 3 The implementation plans are similar or identical. (And) Figure 3 Similarly, catalytically cracked naphtha 154 can be transported to saturation unit 170. However, in Figure 4 In the implementation scheme, light cycle oil 156 is fed to diesel production unit 180 to form diesel 182. Furthermore, according to... Figure 4 A portion of the feed delivered to the mixed feed steam cracking unit 160 can form fuel oil 174, which can be discharged from the condensate treatment system 104. Similarly... Figure 3 As shown in the implementation plan, a portion of the heavy circulating oil 158 can be recycled and transported to the FCC reactor 130.

[0056] Unbound by any particular theory, it is believed that feeding the light fraction stream 122 to the mixed feed steam cracking unit 160 (i.e., bypassing the FCC reactor 130) can increase the yield of fuels and other chemicals such as light olefins. It is believed that in some embodiments, such as those with a cut-off point of 170°C to 200°C in the first separation unit 120, through… Figure 4 The method described in the embodiments allows the condensate feed stream to produce 30% to 50% by weight of fuels (such as gasoline and diesel) and 40% to 60% by weight of high-value chemicals such as light olefins (i.e., ethylene, propylene, butene) and / or aromatics (such as toluene, benzene, and mixed xylenes). Furthermore, it is believed that in some embodiments, such as those with a cut-off point of 230°C to 260°C in the first separation unit 120, through… Figure 4 The method described in the implementation scheme, wherein the condensate feed stream can produce 20% to 40% by weight of fuels (such as gasoline and diesel) and 50% to 70% by weight of high-value chemicals such as light olefins (i.e., ethylene, propylene, butene) and / or aromatics (such as toluene, benzene and mixed xylenes).

[0057] This disclosure includes several aspects, which are listed in aspects 1 to 15.

[0058] Aspect 1, a method for processing condensate feedstock, the method comprising: feeding the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light distillate stream and a heavy distillate stream, wherein: the maximum boiling point of the light distillate stream is approximately equal to the minimum boiling point of the heavy distillate stream; the maximum boiling point of the light distillate stream is between 170°C and 260°C, and the minimum boiling point of the heavy distillate stream is between 170°C and 260°C; and at least 90% by weight of the condensate feedstock is contained in the combination of the light distillate stream and the heavy distillate stream; cracking the heavy distillate stream in an FCC reactor to form an FCC effluent; feeding the FCC effluent to a second separation unit to form a catalytically cracked naphtha stream; and feeding the catalytically cracked naphtha stream and the light distillate stream to a gasoline preparation unit or a mixed feed steam cracking unit.

[0059] Aspect 2, according to the method of aspect 1, wherein one or more of the following are satisfied: the API degree of the condensate feedstock is 45 to 55 degrees; the final boiling point of the condensate feedstock is 550°C to 650°C; or the portion of the condensate feedstock with a boiling point above 565°C is less than or equal to 2 by weight.

[0060] Aspect 3, the method according to any of the foregoing aspects further includes removing at least a portion of the salt from the condensate feedstock before conveying the condensate feedstock to the first separation unit.

[0061] Aspect 4, according to the method of any of the preceding aspects, wherein all of the condensate feedstock is included in the combination of the light fraction stream and the heavy fraction stream.

[0062] Aspect 5, according to the method of any of the preceding aspects, wherein the catalytic cracked naphtha stream and the light fraction stream are transported to the gasoline preparation unit.

[0063] Aspect 6, according to the method of aspect 5, wherein the second separation unit further forms: a fuel gas stream; a stream containing C3-C4 alkanes and C3-C4 light olefins, the stream being conveyed to an olefin separation unit; a light cycle oil stream being conveyed to a diesel production unit; and a heavy cycle oil stream.

[0064] Aspect 7, according to the method of any of the preceding aspects, wherein the catalytic cracked naphtha stream and the light distillate stream are fed to the mixed feed steam cracking unit.

[0065] Aspect 8, according to the method of aspect 7, wherein the second separation unit further forms: a fuel gas stream; a stream containing C3-C4 alkanes and C3-C4 light olefins, the stream being conveyed to an olefin separation unit, the mixed feed steam cracking unit or both; a light cycle oil stream being conveyed to a diesel production unit; and a heavy cycle oil stream.

[0066] Aspect 9, according to the method of aspect 7, wherein the catalytic cracked naphtha stream is first treated in a saturated unit before being delivered to the mixed feed steam cracking unit.

[0067] Aspect 10, the method according to any of the preceding aspects, wherein: the catalytically cracked naphtha and the light distillate stream are fed to the mixed feed steam cracking unit; and the maximum boiling point of the light distillate stream is 230°C to 260°C, and the minimum boiling point of the heavy distillate stream is 230°C to 260°C.

[0068] Aspect 11, according to the method of aspect 10, wherein the second separation unit further forms: a fuel gas stream; a stream containing C3-C4 alkanes and C3-C4 light olefins, the stream being conveyed to an olefin separation unit, a mixed feed steam cracking unit, or both; a light cycle oil stream being conveyed to a diesel production unit; and a heavy cycle oil stream.

[0069] Aspect 12, according to the method of aspect 10, wherein the catalytically cracked naphtha is first processed in a saturated unit before being delivered to the mixed feed steam cracking unit.

[0070] Aspect 13, a method for processing condensate feedstock, the method comprising: conveying the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light distillate stream, a middle distillate stream, and a heavy distillate stream, wherein: the maximum boiling point of the light distillate stream is approximately equal to the minimum boiling point of the middle distillate stream, and the maximum boiling point of the middle distillate stream is approximately equal to the minimum boiling point of the heavy distillate stream; the maximum boiling point of the light distillate stream is between 170°C and 200°C, the minimum boiling point of the middle distillate stream is between 170°C and 200°C, and the maximum boiling point of the middle distillate stream is 230°C. The heavy distillate stream has a minimum boiling point of 230°C to 380°C; and at least 90% by weight of the condensate feedstock is contained in the combination of the light distillate stream, the middle distillate stream, and the heavy distillate stream; the heavy distillate stream is cracked in an FCC reactor to form an FCC effluent; the FCC effluent is fed to a second separation unit to form a catalytically cracked naphtha stream; the catalytically cracked naphtha stream and the light distillate stream are fed to a catalytic reforming unit to form a reforming effluent; and the reforming effluent and the middle distillate stream are fed to a gasoline preparation unit.

[0071] Aspect 14, according to the method of aspect 13, wherein one or more of the following are satisfied: the API degree of the condensate feedstock is 45 to 55 degrees; the final boiling point of the condensate feedstock is 550°C to 650°C; or the portion of the condensate feedstock with a boiling point above 565°C is less than or equal to 2 by weight.

[0072] Aspect 15, the method according to aspect 13 or 14, further includes removing at least a portion of the salt from the condensate feedstock before conveying it to the first separation unit.

[0073] Aspect 16, the method according to any one of Aspects 13 to 15, wherein the second separation unit further forms: a fuel gas stream; a stream containing C3-C4 alkanes and C3-C4 light olefins, the stream being conveyed to an olefin separation unit; a light cycle oil stream being conveyed to a diesel production unit; and a heavy cycle oil stream.

[0074] Aspect 17, a method for processing condensate feedstock, the method comprising: conveying the condensate feedstock to a first separation unit and separating the condensate feedstock into at least a light distillate stream, a middle distillate stream, and a heavy distillate stream, wherein: the maximum boiling point of the light distillate stream is approximately equal to the minimum boiling point of the middle distillate stream, and the maximum boiling point of the middle distillate stream is approximately equal to the minimum boiling point of the heavy distillate stream; the maximum boiling point of the light distillate stream is 170°C to 200°C, the minimum boiling point of the middle distillate stream is 170°C to 200°C; the maximum boiling point of the middle distillate stream is 230°C to 380°C, and the... The minimum boiling point of the heavy distillate stream is 230°C to 380°C; and at least 90% by weight of the condensate feedstock is contained in a combination of the light distillate stream, the middle distillate stream, and the heavy distillate stream; the heavy distillate stream is cracked in an FCC reactor to form an FCC effluent; the FCC effluent is fed to a second separation unit to form at least a catalytically cracked naphtha stream and a light recycle oil stream; the catalytically cracked naphtha stream is fed to a saturation unit; the saturation unit effluent and the light distillate stream are fed to a mixed feed steam cracking unit; and the light recycle oil stream and the middle distillate stream are fed to a kerosene preparation unit.

[0075] Aspect 18, according to the method of aspect 17, wherein one or more of the following are satisfied: the API degree of the condensate feedstock is 45 to 55 degrees; the final boiling point of the condensate feedstock is 550°C to 650°C; or the portion of the condensate feedstock with a boiling point above 565°C is less than or equal to 2 by weight.

[0076] Aspect 19, according to the method of aspect 17 or 18, wherein the catalytic cracked naphtha stream is first treated in a saturated unit before being delivered to the mixed feed steam cracking unit.

[0077] Aspect 20, the method according to any one of Aspects 17 to 19, wherein the second separation unit further forms: a fuel gas stream; a stream comprising C3-C4 alkanes and C3-C4 light olefins, the stream being conveyed to an olefin separation unit, a mixed feed steam cracking unit, or both; and a heavy cycle oil stream.

[0078] For the purpose of illustrating and defining the present disclosure, it should be noted that the terms "about" or "approximately" used herein are intended to reflect the inherent uncertainty of any quantitative comparison, numerical value, measurement result, or other representation. The terms "about" and / or "approximately" in this disclosure are also used to indicate that quantitative numerical values ​​may fluctuate somewhat relative to a specified reference value, and that such fluctuation does not alter the essential function of the subject matter.

[0079] It should be noted that the following claims use "wherein" as a transitional phrase. To clearly define this technical solution, it should be pointed out that the term is used as an open-ended transitional phrase in the claims to introduce a series of structural features, and should be understood in the same way as the more commonly used open-ended prepositional term "comprising / including".

[0080] Any numerical values ​​recorded in this application shall be considered to cover both open-ended implementations consistent with the transitional phrases “comprising” or “including”, and closed or partially closed implementations consistent with the transitional phrases “consisting of” and “substantially consisting of”.

[0081] It should also be noted that the use of the phrase "at least one" in this article should not be interpreted as meaning that the alternative article "a" or "an" is limited to a single component or element.

Claims

1. A method for processing condensate raw materials, the method comprising: The condensate feedstock is conveyed to the first separation unit, whereby the condensate feedstock is separated into at least a light distillate stream and a heavy distillate stream, wherein: The maximum boiling point of the light distillate stream is approximately equal to the minimum boiling point of the heavy distillate stream; The maximum boiling point range of the light distillate stream is 170°C to 260°C, and the minimum boiling point range of the heavy distillate stream is 170°C to 260°C; and At least 90% by weight of the condensate feedstock is contained in the combination of the light distillate stream and the heavy distillate stream; The heavy distillate stream is cracked in an FCC reactor to form an FCC effluent; The FCC effluent is conveyed to a second separation unit to form a catalytically cracked naphtha stream; and The catalytic cracked naphtha stream and the light distillate stream are transported to the gasoline preparation unit or the mixed feed steam cracking unit.

2. The method of claim 1, wherein one or more of the following are satisfied: The API degree of the condensate raw material is 45 to 55 degrees. The final boiling point of the condensate feedstock is 550°C to 650°C; or The portion of the condensate feedstock with a boiling point above 565°C is less than or equal to 2% by weight.

3. The method according to claim 1 or 2, further comprising removing at least a portion of the salt from the condensate feedstock before conveying the condensate feedstock to the first separation unit.

4. The method of any of the preceding claims, wherein all condensate feedstock is contained in a combination of light and heavy distillate streams.

5. The method according to any one of the preceding claims, wherein the catalytic cracked naphtha stream and the light fraction stream are conveyed to the gasoline preparation unit.

6. The method of claim 5, wherein the second separation unit further comprises: Fuel gas logistics; The stream containing C3-C4 alkanes and C3-C4 light olefins is conveyed to the olefin separation unit; The light-cycle oil stream is delivered to the diesel production unit; and Heavy circulation oil logistics.

7. The method according to any one of claims 1 to 4, wherein the catalytic cracked naphtha stream and the light distillate stream are fed to the mixed feed steam cracking unit.

8. A method for processing condensate raw materials, the method comprising: The condensate feedstock is conveyed to the first separation unit, and the condensate feedstock is separated into at least a light distillate stream, a middle distillate stream, and a heavy distillate stream, wherein: The maximum boiling point of the light distillate stream is approximately equal to the minimum boiling point of the middle distillate stream, and the maximum boiling point of the middle distillate stream is approximately equal to the minimum boiling point of the heavy distillate stream. The maximum boiling point range of the light distillate stream is 170°C to 200°C, and the minimum boiling point range of the middle distillate stream is 170°C to 200°C. The maximum boiling point range of the middle distillate stream is 230°C to 380°C, and the minimum boiling point range of the heavy distillate stream is 230°C to 380°C; and At least 90% by weight of the condensate feedstock is contained in the combination of the light distillate stream, the middle distillate stream, and the heavy distillate stream; The heavy distillate stream is cracked in an FCC reactor to form an FCC effluent; The FCC effluent is transported to a second separation unit to form a catalytically cracked naphtha stream; The catalytically cracked naphtha stream and the light distillate stream are fed to a catalytic reforming unit to form a reformate effluent; and The reformate effluent and the middle distillate stream are transported to the gasoline production unit.

9. The method of claim 8, wherein one or more of the following are satisfied: The API degree of the condensate raw material is 45 to 55 degrees. The final boiling point of the condensate feedstock is 550°C to 650°C; or The portion of the condensate feedstock with a boiling point above 565°C is less than or equal to 2% by weight.

10. The method according to claim 8 or 9, further comprising removing at least a portion of the salt from the condensate feedstock before conveying the condensate feedstock to the first separation unit.

11. The method according to any one of claims 8 to 10, wherein the second separation unit further comprises: Fuel gas logistics; The stream containing C3-C4 alkanes and C3-C4 light olefins is conveyed to the olefin separation unit; The light-cycle oil stream is transported to the diesel production unit; and Heavy circulation oil logistics.

12. A method for processing condensate feedstock, the method comprising: The condensate feedstock is conveyed to the first separation unit, and the condensate feedstock is separated into at least a light distillate stream, a middle distillate stream, and a heavy distillate stream, wherein: The maximum boiling point of the light distillate stream is approximately equal to the minimum boiling point of the middle distillate stream, and the maximum boiling point of the middle distillate stream is approximately equal to the minimum boiling point of the heavy distillate stream. The maximum boiling point range of the light distillate stream is 170°C to 200°C, and the minimum boiling point range of the middle distillate stream is 170°C to 200°C. The maximum boiling point range of the middle distillate stream is 230°C to 380°C, and the minimum boiling point range of the heavy distillate stream is 230°C to 380°C; and At least 90% by weight of the condensate feedstock is contained in the combination of the light distillate stream, the middle distillate stream, and the heavy distillate stream; The heavy distillate stream is cracked in an FCC reactor to form an FCC effluent; The FCC effluent is transported to a second separation unit to at least form a catalytic cracking naphtha stream and a light cycle oil stream; The catalytically cracked naphtha stream is transported to the saturation unit; The saturated unit effluent and the light distillate stream are fed to a mixed feed steam cracking unit; and The light circulating oil stream and the middle distillate stream are transported to the kerosene preparation unit.

13. The method of claim 12, wherein one or more of the following are satisfied: The API degree of the condensate raw material is 45 to 55 degrees. The final boiling point of the condensate feedstock is 550°C to 650°C; or The portion of the condensate feedstock with a boiling point above 565°C is less than or equal to 2% by weight.

14. The method according to claim 12 or 13, wherein the catalytic cracking naphtha stream is first treated in a saturation unit before being delivered to the mixed feed steam cracking unit.

15. The method according to any one of claims 12 to 14, wherein the second separation unit further comprises: Fuel gas logistics; A stream containing C3-C4 alkanes and C3-C4 light olefins, which is fed to an olefin separation unit, the mixed feed steam cracking unit, or both; and Heavy circulation oil logistics.

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