Method and system for producing chemicals and fuels using a flow catalytic cracking process from condensate

Abstract

The present disclosure provides a method and system for producing chemicals and fuels from a condensate using a fluid catalytic cracking process. In one embodiment, the method may comprise: providing a hydrocarbon condensate stream to a desalinator to produce a desalinated hydrocarbon condensate stream; providing the desalinated hydrocarbon condensate stream to a classifier to produce a first product stream and one or more second product streams, wherein the first product stream has a boiling point greater than about 350°C and the one or more second product streams each have a boiling point less than about 350°C; providing the first product stream to a catalytic cracker to produce a decomposition product stream; and recirculating the decomposition product stream to the classifier.

Description

Technology Field

[0001] Cross-reference regarding related applications

[0002] This application claims priority and benefits to European application EP23220272.1 filed on December 27, 2023. The contents of the referenced application are incorporated by reference into this application.

[0003] The present disclosure generally relates to a method and system for producing chemicals and fuels using a flow catalytic cracking process from condensate. Background Technology

[0004] Condensate, or natural gas condensate, is a liquid stream of hydrocarbons containing low-density compounds that are gaseous in their original state within a natural gas field and can be condensed into a liquid when separated from light feedstock natural gas. Condensate is a common byproduct of both gas and oil production. Globally, the production of condensate has steadily increased over the past few decades, and this trend is expected to continue. As such, it would be beneficial to maximize the use of condensate whenever possible to produce more valuable products.

[0005] Certain high-value chemicals and fuels are typically produced by the thermal cracking of ethane, propane, butane, and naphtha. For example, about half of all ethene produced is generated by the thermal cracking process. Additionally, these products can be produced through the conversion of heavy feedstocks, such as gas oil or residual oil, using the refinery fluid catalytic cracking (FCC) process. However, as the demand for these basic intermediate compounds increases, there is a corresponding demand for exploring other production sources beyond traditional thermal cracking or FCC processes.

[0006] To address the above problem, the embodiments disclosed herein include a method and a system for producing chemicals and fuels from condensate using an improved FCC-based process. In certain embodiments, the condensate used as a feedstock for producing chemicals and fuels comprises an American Petroleum Institute (API) specific gravity range of about 45 to 55. The embodiments disclosed herein can provide a higher yield of the desired product compared to conventional condensate-based refinery processes with minimal additional equipment. For example, the desired chemical and / or fuel products can be produced with one or more system configurations disclosed herein, which enables the maximization of product yield without an excessive increase in capital expenditure.

[0007] As an example, a specific embodiment of such a system includes a desalinator, a fractionator, and a catalytic cracker. The desalinator removes salt, sand, mud, and sediment from a condensate stream to produce a desalinated condensate stream, which is fed to the fractionator. Accordingly, the fractionator separates the desalinated condensate stream into various fractions, including a heavy product stream fed to the catalytic cracker. The catalytic cracker is operated to break down the heavy product stream into a cracking product stream that is recirculated to the fractionator. In this way, the fractionator can not only output fuel gas from its upper end but also feed liquefied petroleum gas (LPG) to an olefin separation unit. From a first side outlet of the fractionator, a naphtha product stream can be fed to a gasoline production unit. Additionally, from a second side outlet of the fractionator, a diesel stream is split so that a first portion is fed as a diesel blending feedstock and a second portion is fed to be combined with the heavy product stream fed to the catalytic cracker. Accordingly, recirculating the second portion of the heavy product stream and the diesel stream provides improved production of light olefins from the olefin separation unit and improved production of gasoline from the gasoline manufacturing unit.

[0008] As another example, in a specific embodiment, the system disclosed herein includes a desalinator, a classifier, a catalytic cracker, and a catalytic reformer. The desalinator removes salt, sand, mud, and sediment from a condensate stream to produce a desalinated condensate stream, which is fed to a classifier. The classifier separates the desalinated condensate stream into a number of streams, including a heavy product stream fed from the bottom of the classifier to a catalytic cracker. The classifier may also separate light products, including fuel gas and LPG, from the top of the classifier and direct the LPG to an olefin separation unit. As side draws, the classifier may output a naphtha product stream, a light circulating oil stream, and a heavy circulating oil stream. Thus, the classifier directs the heavy circulating oil, which has a higher boiling point than the light circulating oil stream, to be combined with the heavy product stream fed to the catalytic cracker. The classifier may feed a first portion of the naphtha product stream to a gasoline production unit and a second portion of the naphtha product stream to a catalytic reformer. The light circulating oil stream is also directed to a catalytic reformer along with a second portion of the naphtha stream. Thus, the catalytic reformer produces a reformed product stream that is fed to the gasoline production unit. In this way, implementing a catalytic reformer as well as recirculating the heavy product stream and heavy circulating oil enhances the production of light olefins from the olefin separation unit and gasoline production from the gasoline production unit.

[0009] As an additional example, in certain embodiments, the system disclosed herein includes a demineralizer, a classifier, a catalytic cracker, and a steam cracker. The demineralizer, classifier, and catalytic cracker may operate in the same manner as generally discussed above in relation to a system having a demineralizer, a classifier, and a catalytic cracker. Instead of a gasoline production unit, a naphtha product stream from the first side outlet of the classifier is fed to the steam cracker. The steam cracker may also receive all or part of the LPG supplied from the top of the classifier. In this way, the steam cracker produces a second cracking product stream directed to an olefin separation unit. Additionally, the olefin separation unit may directly receive all or the remainder of the LPG supplied from the classifier. Accordingly, the combination of the recirculation of the heavy product stream using the catalytic cracker and the conversion or upgrade of the steam cracker promotes the production of chemicals, such as light olefins, from the olefin separation unit, thereby preferably increasing the chemical yield.

[0010] As an additional example, in certain embodiments, the system disclosed herein includes a desalinator, a classifier, a catalytic cracker, a steam cracker, and a hydrocracker. The desalinator, classifier, catalytic cracker, and steam cracker may operate in the same manner as generally discussed above with respect to a system having a desalinator, classifier, catalytic cracker, and steam cracker. However, the classifier may also separate and output a heavy circulating oil stream, the first portion of which is recirculated to the catalytic cracker together with a heavy product stream. The classifier may also separate and output a light circulating oil stream, which is mixed or combined with a second portion of the heavy circulating oil stream and fed to the hydrocracker. By utilizing a hydrogen supply, the hydrocracker may produce a hydrocracker product stream that is recirculated to the classifier. Thus, a particular system includes a first recirculation loop for a heavy range fraction directed to the catalytic cracker, a second recirculation loop for a medium range fraction directed to the hydrocracker, and a steam cracker for further upgrading the light range component. These processes therefore interact or cooperate to provide improved production and yield of light olefins from the olefin separation unit.

[0011] Accordingly, embodiments disclosed herein include a method for producing chemical and / or fuel products with improved yield. One such method comprises the steps of providing a hydrocarbon condensate stream to a desalinator to produce a desalinated hydrocarbon condensate stream and providing the desalinated hydrocarbon condensate stream to a classifier to produce a first product stream and one or more second product streams. The first product stream has a boiling point greater than about 350°C, and the one or more second product streams each have a boiling point of about 350°C or less. The method further comprises the steps of providing the first product stream to a catalytic decomposer to produce a decomposition product stream and recirculating the decomposition product stream to the classifier.

[0012] In some embodiments, the method further comprises the step of providing at least one of the one or more second product streams to an olefin separation unit to produce an olefin-rich stream. In some embodiments, the method further comprises the step of providing at least one of the one or more second product streams to a steam cracker to produce a second cracking product stream and providing the second cracking product stream to an olefin separation unit to produce an olefin-rich stream. In some embodiments, the olefin-rich stream comprises more than 50 weight percent of ethene, propene, and butene.

[0013] In some embodiments, the method further comprises the step of generating a gasoline stream from the one or more second product streams. In some embodiments, the method further comprises the step of providing one of the one or more second product streams to a catalytic reformer to generate a reformed product stream and the step of supplying the reformed product stream to a gasoline blending unit to generate the gasoline stream. In some embodiments, the method further comprises the step of providing one of the one or more second product streams to a hydrocracker to generate a hydrocracker product stream and the step of recirculating the hydrocracker product stream to the classifier. In some embodiments, the hydrocarbon condensate stream comprises natural gas condensate having an American Petroleum Institute (API) specific gravity of about 45 to about 55.

[0014] Additionally, embodiments disclosed herein include a system for producing chemical and / or fuel products with improved yield. One such system includes a desalinator configured to receive a hydrocarbon condensate stream and produce a desalinated hydrocarbon condensate stream. The system further includes a classifier configured to receive the desalinated hydrocarbon condensate stream from the desalinator and produce a first product stream and one or more second product streams. The first product stream has a boiling point greater than about 350°C, and the one or more second product streams each have a boiling point of about 350°C or less. The system further includes a catalytic decomposer configured to receive the first product stream, produce a decomposition product stream, and recirculate the decomposition product stream to the classifier.

[0015] In some embodiments, the system further comprises an olefin separation unit configured to receive at least one of the one or more second product streams and produce an olefin-rich stream. In some embodiments, the system further comprises a steam cracker configured to receive at least one of the one or more second product streams and produce a second decomposition product stream, and an olefin separation unit configured to receive the second decomposition product stream and produce an olefin-rich stream. In some embodiments, the olefin-rich stream comprises more than 50 weight percent of ethene, propene, and butene.

[0016] In some embodiments, the system further comprises a catalytic reformer configured to receive one of the one or more second product streams and produce a reformed product stream, and a gasoline blending unit configured to receive at least the reformed product stream and produce a gasoline stream. In some embodiments, the system further comprises a hydrocracker configured to receive one of the one or more second product streams, produce a hydrocracking product stream, and recirculate the hydrocracking product stream to the classifier. In some embodiments, the hydrocarbon condensate stream has an API specific gravity of about 45 to about 55.

[0017] The aspects and advantages of these exemplary embodiments and other embodiments are discussed in detail in this specification. Furthermore, it should be understood that the foregoing information and the following detailed description are merely exemplary examples of various aspects and embodiments and are intended to provide an overview or framework for understanding the nature and characteristics of the claimed aspects and embodiments. Accordingly, these and other purposes, along with the advantages and features of this disclosure, will become apparent from the following description and the accompanying drawings. Additionally, it should be understood that the features of the various embodiments described in this specification are not mutually exclusive and may exist in various combinations and permutations. Brief explanation of the drawing

[0018] The accompanying drawings, included to provide further understanding of the embodiments of the present disclosure, are incorporated into this specification and constitute part of this specification. They serve to illustrate the embodiments of the present disclosure and, together with the detailed description, explain the principles of the embodiments discussed in this specification. No attempt is made to depict the structural details of the present disclosure in greater detail than may be necessary for a basic understanding of the embodiments discussed in this specification and the various ways in which they may be practiced. In accordance with general practice, the various features of the drawings discussed below are not necessarily drawn to scale. The dimensions of various features and elements within the drawings may be enlarged or reduced to more clearly illustrate the embodiments of the present disclosure. FIG. 1 is a block diagram of an embodiment of a method for producing chemicals and fuel from condensate according to one embodiment of the present disclosure. FIG. 2 is a schematic diagram of a system having a desalinator, a classifier, and a catalytic decomposer according to one embodiment of the present disclosure. FIG. 3 is a schematic diagram of a system having a desalinator, a classifier, a catalytic decomposer and a catalytic reformer according to one embodiment of the present disclosure. FIG. 4 is a schematic diagram of a system having a desalinator, a classifier, a catalytic decomposer and a steam decomposer according to one embodiment of the present disclosure. FIG. 5 is a schematic diagram of a system having a desalinator, a classifier, a catalytic decomposer, a steam decomposer, and a hydrodecomposer according to one embodiment of the present disclosure. Specific details for implementing the invention

[0019] This disclosure describes various embodiments related to methods and systems for producing chemicals and fuels from condensate, such as implementing a catalytic cracking process integrated with pretreatment and other upgrade processes. As discussed above, there is an increasing demand for more effective utilization of condensate for the production of fuels and chemicals. To date, many researchers have studied the use of condensate for blending with conventional crude oil in refinery processes. For example, the availability of pretreatment, hydrotreatment, and hydrocracking equipment can contribute to the regularity of condensate being used in this manner, which limits it to a level lower than the condensate's full potential. In some cases, most of the products produced by blending condensate with conventional crude oil are C 5+ It contains naphtha-range components similar to the product. However, various significant changes, such as modified process conditions, equipment redesign, and / or changes in catalyst type or composition, may be required to achieve higher chemical yields than previously available by subjecting additional processing steps after blending condensate with crude oil to produce chemicals.

[0020] As disclosed herein, various embodiments of the present disclosure produce chemicals and fuels from condensates with improved yield and efficiency. Generally, specific embodiments disclosed herein include desalting a hydrocarbon condensate stream and classifying said desalted hydrocarbon condensate stream to produce (1) one or more light streams used to produce olefins and / or fuels and (2) a heavy stream that is recirculated to a classifier after catalytic cracking. In specific embodiments, said one or more light streams include any suitable stream disclosed herein, such as a heavy circulating oil stream, a light circulating oil stream, a diesel product stream, a naphtha product stream, a fuel gas stream, an LPG stream, or any combination thereof. The systems and methods disclosed herein include a number of configurations, each of which is suitable for converting condensate-based feedstocks to produce high-value chemicals such as light olefins and aromatics. The above product can be efficiently manufactured based on providing a demineralized hydrocarbon stream to a classifier, recirculating the heavy or lower stream therefrom to a catalytic cracker, and then recirculating it back to the classifier. Specific embodiments include implementing the catalytic cracker as a central unit in a flow catalytic cracking process.

[0021] More specifically, the condensate feedstock is desalinated in a suitable desalinator to prepare the condensate for further processing, such as removing salts, sand, mud, and / or precipitates. In some embodiments, the condensate comprises a range of hydrocarbons from those containing three or more carbon atoms to those boiling above 565°C. In some embodiments, the condensate has an API specific gravity range of 45 to 55. After desalination and / or decontamination, the condensate feedstock is fed to a classifier or a classification tower for processing. The classifier produces classified fractions that, depending on the product specifications, can be further processed in a catalytic cracker (having a riser or downer configuration), a reformer unit, and / or a hydrocracker unit. In practice, the present embodiment includes various equipment combinations, such as a catalytic cracker with or without a reformer unit and a hydrocracker unit. Additionally, certain embodiments include integration with a steam cracker or a mixed feedstock steam cracker to further increase the production of light olefins and aromatics.

[0022] Accordingly, the present disclosure addresses a number of challenges previously faced in the industry. For example, certain embodiments provide the production of chemicals and fuels from condensates using a minimum number of process units while maximizing selectivity for high-value products. In certain embodiments, a process configuration is implemented that maximizes fuel production from condensates while also producing chemicals. Additionally, in certain embodiments, a process configuration is implemented that maximizes chemical production from condensates. For example, certain embodiments include processing the condensate feedstock with flow catalytic cracking integrated with downstream units, such as a classification unit, without relying on a number of additional separation units. In some embodiments, improved or optimized ratios of rare-earth modified USY catalysts and ZSM-5-based additives are provided to achieve maximum production of chemicals and fuels in the catalytic cracker.

[0023] Additional embodiments may be described and disclosed. In the following description, numerous details are provided to provide a thorough understanding of the various embodiments. In other cases, well-known processes, apparatuses, and systems may not be described in specific details to avoid unnecessarily obscuring the various embodiments. Additionally, examples of various embodiments may omit specific features or details to avoid obscuring the various embodiments.

[0024] This description may use phrases such as “in a specific embodiment,” “in various embodiments,” “in one embodiment,” or “in embodiments,” which may each refer to one or more of the same or different embodiments. Additionally, terms such as “comprising,” “including,” and “having” as used in relation to the embodiments of this disclosure are synonyms. The term “about” refers to a range of values ​​that includes a specific value which a person skilled in the art would consider to be reasonably similar to the specific value. In an embodiment, “about” refers to a value within a standard deviation using measurements generally accepted in the art. In one non-limiting embodiment, where the term “about” is used with a specific value, “about” refers to a range extending up to ±10% of the specific value, alternatively ±5% of the specific value, alternatively ±1% of the specific value, or alternatively ±0.5% of the specific value. In an embodiment, “about” refers to a specific value.

[0025] As used in claims and / or specification, “removing,” “removed,” “reducing,” “reduced,” or any variation thereof comprises any measurable reduction of one or more components in a mixture to achieve a desired result. When used in claims or specification with the terms “comprising,” “including,” “containing,” or “having,” the use of the word “a” or “an” may mean “one,” but is also consistent with the meanings of “one or more,” “at least one,” and “one or more than one.” As used herein, the term “plural” refers to two or more items or components. The terms “weight%,” “volume%,” or “molar%” each refer to the weight, volume, or mole percentage of the component based on the total weight, total volume, or total moles of the material containing the component. As a non-limiting example, 10 grams of component in 100 grams of material is 10 weight% of the component.

[0026] Embodiments of the methods, systems, and compositions described herein are used to improve the production of chemicals and fuels from condensates using a flow catalytic cracking process. In a specific embodiment, the method comprises the steps of providing a hydrocarbon condensate stream to a desalinator to produce a desalinated hydrocarbon condensate stream and providing the desalinated hydrocarbon condensate stream to a classifier to produce a first product stream (or heavy stream) and one or more second product streams (or light streams). The first product stream may have a boiling point greater than about 350°C, and the one or more second product streams may each have a boiling point less than about 350°C. The method comprises the steps of providing the first product stream to a catalytic cracker to produce a cracking product stream and recirculating the cracking product stream to the classifier.

[0027] The disclosed embodiments also include a method for producing chemicals and fuels from a condensate using a flow catalytic cracking process. FIG. 1 is a block diagram of an embodiment of a method (100) for producing at least an olefin-rich stream based on the conversion and / or upgrading of a hydrocarbon condensate stream. In some embodiments, the method (100) may correspond to specific embodiments of elements and systems generally discussed in relation to FIGS. 2 through 5. The method includes the step (102) of providing the hydrocarbon condensate stream to a desalinator. In some embodiments, the hydrocarbon condensate stream may have an API specific gravity of about 45 to about 55. Additionally, by removing salts that would otherwise contaminate or negatively affect operation, the desalination of the hydrocarbon condensate stream generally increases the efficiency and / or yield of the product produced through the method (100). In some examples, the desalinator removes additional materials or contaminants such as sand, mud and / or sediment. The method comprises the step (104) of providing the demineralized hydrocarbon condensate stream to a classifier to produce a first product stream and one or more second product streams. The first product stream has a boiling point greater than about 350°C, and the one or more second product streams each have a boiling point of about 350°C or less. As discussed above, the first product stream may correspond to a heavy product stream. Additionally, the one or more second product streams may include any suitable one or combination of the other streams discussed above, such as a heavy circulating oil stream, a light circulating oil stream, a diesel product stream, a naphtha product stream, a fuel gas stream, an LPG stream, or any combination thereof.The above method includes the step (106) of providing the first product stream to a catalytic decomposer to generate a decomposition product stream, and the step (108) of recirculating the decomposition product stream to the classifier.

[0028] Additionally, the method comprises the step (110) of providing at least one of the one or more second product streams to an olefin separation unit to produce an olefin-rich stream. The olefin-rich stream may contain more than 50% by weight of ethene (or ethylene), propene (or propylene), and butene. The method may further comprise additional steps to increase or improve the yield of olefins and high-value chemicals. For example, in some embodiments, the method further comprises the step of providing at least one of the one or more second product streams to a steam cracker to produce a second cracking product stream and providing the second cracking product stream to the olefin separation unit. Non-limiting examples of steam crackers are illustrated as 470 and 570 in FIGS. 4 and FIGS. 5, respectively. In some of these embodiments, the method comprises the steps of providing one of the one or more second product streams to a hydrocracker to produce a hydrocracker product stream and recirculating the hydrocracker product stream to the classifier, which is the same as the mild hydrocracker (560) of FIG. 5.

[0029] In some embodiments, the method further comprises the step of generating a gasoline stream from one or more second product streams. In some of these embodiments, the method comprises the step of providing one of the one or more second product streams to a catalytic reformer to generate a reformed product stream, and the step of supplying the reformed product stream to a gasoline blending unit to generate the gasoline stream. Non-limiting examples comprising gasoline production are illustrated in FIGS. 2 and 3.

[0030] FIG. 2 is a schematic diagram of a system (200) for producing chemicals and fuels from a condensate through a desalinator, a classifier, and a catalytic decomposer according to one embodiment of the present disclosure. In certain embodiments, the system (200) increases the yield of the desired product without excessively increasing the capital expenditure (capex) for the system (200). The system (200) includes various operating units arranged in a suitable configuration for processing a condensate stream (202), a hydrocarbon condensate feedstock, or a crude oil condensate. Certain embodiments of the condensate stream (202) include a feedstock having an API specific gravity range of 45 to 55. In some embodiments, the condensate stream (202) includes a final boiling point (FBP) of 650°C. In certain embodiments, the condensate stream (202) includes water-soluble salts such as chlorides and other minerals. For example, a specific condensate stream (202) contains a salt concentration in the range of 1 to 15 pounds (PTB) per 1,000 barrels.

[0031] The system (200) comprises a desalinator (204) having a first inlet for receiving the condensate stream (202) and a first outlet for outputting a desalinated condensate stream (206). The desalinator (204) may remove salt from the condensate stream (202) through any suitable process for purifying the condensate stream (202) for further upgrades. For example, the desalinator (204) may include a tank or mixer in which the condensate stream (202) is mixed with fresh water or a treated water stream to provide a homogeneous or uniform mixture. In a specific embodiment, the homogeneous mixture is heated to a temperature close to the boiling point of the condensate stream (202), e.g., 78 to 80°C. That is, a specific embodiment of the desalinator (204) heats the homogeneous mixture to an initial boiling point temperature while keeping the homogeneous mixture in a liquid state. In the homogeneous mixture, the water-soluble salt generally moves from the organic phase corresponding to the condensate stream (202) to the aqueous phase corresponding to the water stream. The desalination process can remove most of the salt from the organic phase. In some embodiments, the organic phase is desalinated to a salt concentration of less than 1 PTB. In certain embodiments, the desalinator (204) may perform a single-stage or double-stage desalination process to achieve a target salt concentration in the organic phase.

[0032] After mixing and heating, the organic phase and the aqueous phase may be transferred to a sedimentation tank of the desalinator (204), where the phases are separated. In some embodiments, the desalinator (204) includes an electric device and / or chemical additive to facilitate the separation of the organic phase and the aqueous phase. Thus, the organic phase may be output by the desalinator (204) as the desalinated condensate stream (206). The removal of salt from the condensate stream (202) preferably increases the efficiency and / or yield of the products produced by the system (200), including chemical and / or fuel products. Depending on the source or location from which the condensate stream (202) originates, the condensate stream (202) may also contain other impurities, such as nitrogen and / or sulfur compounds. As such, a specific embodiment of the system (200) additionally includes a hydrotreater for hydrotreating the condensate stream (202) based on the content of other impurities in the condensate stream (202). A specific example of the desalinator (204) can also remove sand, mud and / or sediment present in the condensate stream (202).

[0033] As described, the system (200) comprises a classifier (210) having a second inlet for receiving the desalinated condensate stream (206) from the desalinator (204). In a specific embodiment, the classifier (210) comprises a preheater for raising the temperature of the desalinated condensate stream (206) before classification. The classifier (210) is or comprises a classification tower for separating the desalinated condensate stream (206) into various fractions, streams, and / or products. The classification tower may include any suitable arrangement of packing and / or trays to facilitate the separation of products within it. An illustrated embodiment of the classifier (210) comprises: (i) a second outlet or lower outlet for outputting a heavy product stream (212) or lower end fraction; (ii) a third outlet or first side outlet for outputting a diesel product stream (214); (iii) a fourth outlet or second side outlet for outputting a naphtha product stream (220); and (iv) a fifth outlet or upper outlet for outputting an upper product stream or light end fraction comprising a fuel gas stream (222) and an LPG stream (224). It should be understood that the specific arrangement of inlets and outlets for the classifier (210) and other equipment is provided as an exemplary example and is non-limiting and can be adjusted based on any suitable process characteristics.

[0034] In certain embodiments, a catalytic cracker (230) or a flow catalytic cracker is provided to the system (200) to increase the yield of fuel and chemicals from the demineralized condensate stream (206). As the highest heavy fraction, the heavy product stream (212) has the highest boiling point and is directed from the second outlet of the classifier (210) to the third inlet of the catalytic cracker (230). In some embodiments, the heavy product stream (212) has a boiling point higher than 350°C. In certain embodiments, the heavy product stream (212) contains slurry oil and / or atmospheric residue oil. The system (200) may feed the heavy product stream (212) to the catalytic cracker (230) as a new feedstock along a recirculation loop within the system (200). In this way, any high molecular weight compound in the stream provided to the catalytic decomposer (230), such as that present in the heavy product stream (212), can be recycled until consumed to produce a more valuable product.

[0035] In some embodiments, the catalytic decomposer (230) decomposes the heavy product stream (212) to convert the heavy product stream (212) into a decomposition product stream (232). In some embodiments, the catalytic decomposer (230) may include a sixth outlet that outputs the decomposition product stream (232) and supplies the decomposition product stream (232) to a fourth inlet of the classifier (210). As such, the decomposition product stream (232) may be recirculated or supplied back to the classifier (210) to yield different fractions or products disclosed herein, including chemicals and fuels. In some embodiments, the catalytic decomposer (230) also outputs exhaust gas (234) generated during the decomposition process. In certain embodiments, the catalytic decomposer (230) yields about 20 to 40 percent of light olefins such as ethene, propene, and butene. In some embodiments, the catalytic decomposer (230) and the classifier (210) operate together as an integrated processing unit, such as a flow catalytic decomposition complex.

[0036] Looking at the progressively lighter fractions generated by the classifier (210), the diesel product stream (214) may be output from the third outlet of the classifier (210) as a fraction containing a medium fraction range component. In some embodiments, the diesel product stream (214) comprises a circulating oil having a boiling point between 185 and 350°C. The diesel product stream (214) may be divided into two parts, such as a first part combined with the heavy product stream (212) that is recirculated to the catalytic cracker (230). In certain embodiments, the second part of the diesel product stream (214) is provided from the system (200) as a diesel blending feedstock (215). In certain embodiments, the diesel blending feedstock (215) may correspond to a suitable fuel product.

[0037] The naphtha product stream (220) may be discharged from the fourth outlet of the classifier (210) as a fraction containing light naphtha and heavy naphtha, including cracked naphtha produced in the catalytic cracker (230). In certain embodiments, the naphtha product stream (220) exhibits a naphtha / liquid yield of about 30 to 40 weight percent, such as based on the naphtha-rich content of the condensate stream (202) and / or the cracked product stream (232). In some embodiments, the naphtha product stream (220) is supplied to a gasoline production unit (276) or a fifth inlet of a refinery gasoline pool. The gasoline production unit (276) may produce and discharge a gasoline stream (278) or product, which is discharged from the seventh outlet of the gasoline production unit (276). In a specific embodiment, the gasoline stream (278) can be transported from the system (200) as a suitable fuel product.

[0038] The upper product stream of the classifier (210), output from the fifth outlet of the classifier (210), contains fuel gas (222) and / or LPG (224). For example, in certain embodiments, the upper product stream contains hydrogen, methane, ethane, ethene, propane, propene, butane and / or butene. The upper product stream may generally contain compounds that remain in a gaseous state under conditions within the classifier (210), such as compounds related to fuel gas and / or LPG. In certain embodiments, the upper product stream provides about 5 to 20 weight percent of the total output from the classifier (210). In some embodiments, the system (200) includes a separation vessel or splitter for separating the fuel gas stream (222) from the LPG stream (224), each provided from the fifth outlet of the classifier (210). In a specific embodiment, the fuel gas stream (222) can be transported from the system (200) as a suitable fuel product.

[0039] In some embodiments, the LPG stream (224) generally contains a high content of light olefins such as propene. In certain embodiments, the LPG stream (224) may be supplied to a sixth inlet of an olefin separation unit (280), which includes an eighth outlet that outputs an olefin stream (282) or a light olefin stream therefrom. As should be understood, the disclosed embodiment of the system (200) produces light olefins in a preferably increased yield compared to a previously available system without this configuration of the catalytic cracker (230). Additionally, the system (200) may provide a total fuel yield that is generally about 40 to 60 weight percent in some embodiments. In some embodiments, the system (200) produces a minimum fuel recovery rate or lower threshold recovery rate of about 35 to 45 weight percent. Additionally, fuel can be separated directly from the demineralized condensate stream (206), thereby reducing the capital expenditure of the system (200) compared to a system that relies on additional separation equipment.

[0040] FIG. 3 is a schematic diagram of a system (300) for producing chemicals and fuels from a condensate through a demineralizer, a classifier, a catalytic cracker, and a catalytic reformer according to one embodiment of the present disclosure. In a specific embodiment, the system (300) increases the yield of the desired product through catalytic reforming, upgrading a compound related to diesel or a specific light circulating oil into gasoline. The system (300) includes a specific operating unit corresponding to that discussed above in relation to FIG. 2. For clarity, the description of the specific operating unit is not repeated in detail herein.

[0041] The system (300) processes the condensate stream (302) into desired fuels and chemicals. In a specific embodiment, the condensate stream (302) is supplied to a first inlet of a desalinator (304). The desalinator may operate or be operable to remove salt from the condensate stream (302) and output a desalinated condensate stream (306) through a first outlet of the desalinator (304). Accordingly, the desalinated condensate stream (306) is supplied to a second inlet of a classifier (310). The classifier (310) may separate the products within it based on their boiling points. For example, in some embodiments, the classifier (310) comprises (i) a second outlet for outputting a heavy product stream (312), (ii) a third outlet for outputting a heavy circulating oil stream (316), (iii) a fourth outlet for outputting a light circulating oil stream (318), (iv) a fifth outlet for outputting a naphtha product stream (320), and (v) a sixth outlet for outputting an upper product stream.

[0042] As previously described, the heavy product stream (312) is supplied from the second outlet of the classifier (310) to the third inlet of the catalytic decomposer (330). In some embodiments, the heavy product stream (312) has a boiling point higher than 350°C. In some embodiments, the catalytic decomposer (330) decomposes the heavy product stream (312) into a decomposition product stream (332), which is supplied through the seventh outlet of the catalytic decomposer (330) to the fourth inlet of the classifier (310). The catalytic decomposer (330) may also output exhaust gas (334). In certain embodiments, the heavy circulating oil stream (316) is combined with the heavy product stream (312) and recirculated to the catalytic decomposer (330). In certain embodiments, the heavy circulating oil stream (316) has a boiling point in the range of 225 to 350°C.

[0043] As discussed above, the upper product stream from the classifier (310) may contain fuel gas and / or LPG. In some embodiments, the fuel gas stream (322) is separated from the upper product stream and provided as a suitable fuel product. Additionally, the LPG stream (324) may be separated from the upper product stream and directed to a fifth inlet of the olefin separation unit (380). In some embodiments, the olefin separation unit (380) includes an eighth outlet that outputs an olefin stream (382) as a suitable chemical product.

[0044] In the illustrated embodiment, the light circulating oil stream (318) and the naphtha product stream (320) are used for gasoline production. For example, the naphtha product stream (320) may be divided into two parts, including a first part supplied to the sixth inlet of the catalytic reformer (350) and a second part supplied to the seventh inlet of the gasoline production unit (376). In a specific embodiment, the naphtha product stream (320) exhibits a naphtha / liquid yield of about 30 to 40 weight percent, such as based on the naphtha-rich content of the condensate stream (302) and / or the cracking product stream (332). Additionally, the light circulating oil stream (318) may be combined with the first part of the naphtha product stream (320) directed to the catalytic reformer (350). In a specific embodiment, the light circulating oil stream (318) has a boiling point in the range of 185 to 225°C.

[0045] In certain embodiments, the catalytic reformer (350) can be operated to convert or upgrade the first portion of the light circulating oil stream (318) and the naphtha product stream (320) into a reformed product stream (352). For example, the catalytic reformer (350) can increase the octane rating of the compounds within it, such as by using a hydrogenation-dehydrogenation catalyst with a fixed-bed reactor in the presence of hydrogen. That is, in some embodiments, catalytic reforming converts a low-octane effluent stream into a high-octane aromatic hydrocarbon. In certain embodiments, the catalytic reformer (350) operates at a reaction temperature of 450 to 520°C and a reaction pressure of 5 to 45 atm. In some embodiments, the catalytic reformer includes a hydrogen-to-hydrocarbon molar ratio in the range of 3 to 8. In some embodiments, the catalyst used in the catalyst reformer (350) may be supported on alumina and may contain any suitable precious metal such as platinum chloride, tin-promoted palladium, tungsten, nickel, rhodium and / or cobalt supported on alumina.

[0046] The catalytic reformer (350) includes a ninth outlet for outputting the reforming product stream (352). In some embodiments, the reforming product stream (352) is supplied to the eighth inlet of the gasoline production unit (376). Thus, the gasoline production unit (376) can produce a gasoline stream (378) by utilizing both the reforming product stream (352) and the second portion of the naphtha product stream (320). In certain embodiments, the gasoline stream (378) is output from the gasoline production unit (376) through a tenth outlet as a suitable fuel product. In certain embodiments, the inclusion of the catalytic reformer (350) further increases the total fuel production for the system (300) by about 50 to 70 weight percent.

[0047] FIG. 4 is a schematic diagram of a system (400) for producing chemicals and fuels from a condensate through a desalinator, a classifier, a catalytic decomposer, and a steam decomposer, according to one embodiment of the present disclosure. In a specific embodiment, the system (400) increases the production of chemicals based on integration with the steam decomposer. The system (400) includes a specific operating unit corresponding to that discussed above in relation to FIG. 2. For clarity, the description of the specific operating unit is not repeated in detail herein.

[0048] The above system (400) can generally process a condensate stream (402) into a desired product, including an increased chemical yield. In a specific embodiment, the condensate stream (402) is supplied to a first inlet of a desalinator (404), which removes salt from the condensate stream (402) and outputs a desalinated condensate stream (406) through a first outlet of the desalinator (404). The desalinated condensate stream (406) can be supplied to a second inlet of a classifier (410). Thus, the classifier (410) separates the products or compounds within it based on their respective boiling points. For example, in some embodiments, the classifier (410) includes (i) a second outlet for outputting a heavy product stream (412), (ii) a third outlet for outputting a diesel product stream (414) or a circulating oil stream, (iii) a fourth outlet for outputting a naphtha product stream (420), and (iv) a fifth outlet for outputting an upper product stream including a fuel gas stream (422) and an LPG stream (424).

[0049] As previously described, the heavy product stream (412) is supplied from the second outlet of the classifier (410) to the third inlet of the catalytic cracker (430), and the catalytic cracker breaks the heavy product stream (412) into a cracking product stream (432). The catalytic cracker (430) may also output exhaust gas (434). The system (400) may supply the cracking product stream (432) from the seventh outlet of the catalytic cracker (430) to the fourth inlet of the classifier (410). In a specific embodiment, the diesel product stream (414) is output from the third outlet of the classifier (410) as a fraction containing a middle fraction range component. In a specific embodiment, the diesel product stream (414) is divided into two parts, such as a first part that is combined with the heavy product stream (412) that is recirculated to the catalytic cracker (430). In a specific embodiment, a second portion of the diesel product stream (414) is provided from the system (400) as a diesel blending feedstock (415). In a specific embodiment, the diesel blending feedstock (415) may correspond to a suitable fuel product.

[0050] In certain embodiments, all or part of the naphtha product stream (420) is used for the production of chemicals instead of gasoline. In some embodiments, the naphtha product stream (420) corresponds to about 30 to 45 weight percent of the total product from the classifier (410). The naphtha product stream (420) is output from the fourth outlet of the classifier (410), and in certain embodiments, a first portion of the naphtha product stream (420) is supplied to a mixed feedstock steam cracker (470) or a fifth inlet of a steam cracker. In certain embodiments, a second portion of the naphtha product stream (420) is output by the system (400) as a suitable fuel product, such as naphtha blending feedstock (421). In some embodiments, the upper product stream from the classifier (410) contains fuel gas and / or LPG. In some embodiments, the fuel gas stream (422) is separated from the upper product stream and provided as a suitable fuel product. Additionally, the LPG stream (424) can be separated from the upper product stream, wherein the first portion of the LPG stream (424) is directed to the sixth inlet of the mixed raw material steam decomposer (470).

[0051] The mixed feedstock steam cracker (470) can be operated to crack the first portion of the LPG stream (424) and the first portion of the naphtha product stream (420) to produce a second cracking product stream (472). The mixed feedstock steam cracker (470) can process the compounds within it at high temperatures to convert light fraction / naphtha range components into more useful or higher value products. In certain embodiments, the mixed feedstock steam cracker (470) operates with varying propene-to-ethene weight ratios in the range of 0.4 to 0.6 in the outlet product mixture. In certain embodiments, the outlet temperature of the mixed feedstock steam cracker (470) is in the range of 800 to 850°C. Additionally, in some embodiments, the operating pressure of the mixed feedstock steam cracker (470) is maintained slightly higher than atmospheric pressure, such as within 1%, 3%, or 5% of atmospheric pressure.

[0052] The second decomposition product stream (472) generated by the mixed feedstock steam decomposer (470) may include a variety of products. In some embodiments, the products of the second decomposition product stream (472) include ethene, propene, aromatics (e.g., benzene, toluene, xylene, ethylbenzene, styrene, etc.), hydrogen, methane, carbon monoxide, carbon dioxide, heavier organic components, and other organic components. In certain embodiments, certain light compounds formed in the mixed feedstock steam decomposer (470), including products such as ethane, propane, butane, pentane, or alkanes, may be fed back to the mixed feedstock steam decomposer (470) as recirculated feedstock. In some embodiments, the mixed feedstock steam decomposer (470) includes a seventh outlet for outputting the second decomposition product stream (472).

[0053] The second decomposition product stream (472) may be mixed or combined with the second portion of the LPG stream (424) and supplied to the seventh inlet of the olefin separation unit (480). The olefin separation unit (480) may include an eighth outlet that outputs the olefin stream (482) as a suitable chemical product with an increased chemical yield compared to a system without the mixed feedstock steam cracker (470). In practice, in addition to fuel separation from the condensate processed by the classifier (410), the system (400) utilizing the mixed feedstock steam cracker (470) can increase the production of chemicals by about 30 to 50 weight percent.

[0054] FIG. 5 is a schematic diagram of a system (500) for producing chemicals and fuels from a condensate through a desalinator, a classifier, a catalytic decomposer, a steam decomposer, and a hydrodecomposer, according to one embodiment of the present disclosure. In a specific embodiment, the system (500) increases the production of chemicals based on the integration of the steam decomposer and the hydrodecomposer. The system (500) includes a specific operating unit corresponding to that discussed above in relation to FIG. 4. For clarity, the description of the specific operating unit is not repeated in detail herein.

[0055] The system (500) processes a condensate stream (502) into a desired product with increased chemical yield. In a specific embodiment, the condensate stream (502) is supplied to a first inlet of a desalinator (504), which removes salt from the condensate stream (502) and outputs a desalinated condensate stream (506) through a first outlet of the desalinator (504). The desalinated condensate stream (506) is supplied to a second inlet of a classifier (510), which separates the products within based on their boiling points. For example, in some embodiments, the classifier (510) comprises (i) a second outlet for outputting a heavy product stream (512), (ii) a third outlet for outputting a heavy circulating oil stream (516), (iii) a fourth outlet for outputting a light circulating oil stream (518), (iv) a fifth outlet for outputting a naphtha product stream (520), and (v) a sixth outlet for outputting an upper product stream.

[0056] The heavy product stream (512) may be supplied from the second outlet of the classifier (510) to the third inlet of the catalytic cracker (530), and the catalytic cracker breaks the heavy product stream (512) into a cracking product stream (532). The catalytic cracker (530) may also output exhaust gas (534). In some embodiments, the system (500) supplies the cracking product stream (532) from the seventh outlet of the catalytic cracker (530) to the fourth inlet of the classifier (510). In some embodiments, the system (500) divides the heavy circulating oil stream (516) into two parts, the first part of which is combined with the heavy product stream (512) and recirculated to the catalytic cracker (530). In some embodiments, the second part of the heavy circulating oil stream (516) is supplied to the fifth inlet of the mild hydrocracker (560). Additionally, the light circulating oil stream (518) may be mixed or combined with the second portion of the heavy circulating oil stream (516) and supplied to the fifth inlet of the mild hydrocracker (560). In a specific embodiment, the heavy circulating oil stream (516) has a boiling point in the range of 245 to 350°C and the light circulating oil stream (518) has a boiling point in the range of 185 to 245°C.

[0057] In some embodiments, the mild hydrocracker (560) facilitates the conversion of aromatic compounds previously produced in the catalytic cracker (530). For example, the mild hydrocracker (560) may hydrocracker the second portion of the heavy circulating oil stream (516) and the light circulating oil stream (518) to produce a hydrocracker product stream (562). In certain embodiments, the mild hydrocracker (560) operates at a reaction pressure of 50 to 150 bar and a reaction temperature of 300 to 500°C. In some embodiments, the mild hydrocracker (560) comprises a fixed-bed reactor provided with a catalyst and hydrogen (564) supply, and may be used as either a riser configuration or a downer configuration. In a specific embodiment, the mild hydrocracker (560) comprises Ni-WO3 / Al2O3, Ni-WO3 / zeolite, and a precious metal supported catalyst, such as a catalyst such as Pt or Pd supported on zeolite (USY). In a specific embodiment, the main product produced by the mild hydrocracker (560) comprises jet fuel, diesel, LPG, and / or naphtha.

[0058] In a specific embodiment, the hydrocracking product stream (562) of the mild hydrocracking unit (560) is discharged through the eighth outlet of the mild hydrocracking unit (560) and supplied to the sixth inlet of the classifier (510), thereby recirculating the target compound inside until it is exhausted. In a specific embodiment, the hydrocracking product stream (562) is supplied to any suitable additional or alternative location within the system (500). For example, in a specific embodiment, the hydrocracking product stream (562) may be supplied to the catalytic hydrocracking unit (530) together with the heavy product stream (512). In some embodiments, the hydrocracking product stream (562) may be supplied to the second or fourth inlet of the classifier (510) instead of a separate inlet. In any case, the system (500) including the mild hydrocracker (560) accordingly provides a second recirculation loop for further upgrading the compound into a valuable chemical product.

[0059] In some embodiments, all or part of the naphtha product stream (520) is used for the production of chemicals instead of gasoline. The naphtha product stream (520) is output from the fifth outlet of the classifier (510), and in certain embodiments, a first portion of the naphtha product stream (520) is supplied to the seventh inlet of the mixed feedstock steam cracker (570). In certain embodiments, a second portion of the naphtha product stream (520) is output by the system (500) as a suitable fuel product, such as naphtha blending feedstock (521). In some embodiments, the upper product stream from the classifier (510) contains fuel gas and / or LPG. In some embodiments, the fuel gas stream (522) is separated from the upper product stream and provided as a suitable fuel product. Additionally, the LPG stream (524) can be separated from the upper product stream, wherein the first portion of the LPG stream (524) is directed to the eighth inlet of the mixed raw material steam decomposer (570).

[0060] As previously described, the mixed feedstock steam cracker (570) can crack the first portion of the LPG stream (524) and the first portion of the naphtha product stream (520) to produce a second cracking product stream (572), which can be output through the ninth outlet of the mixed feedstock steam cracker (570). In some embodiments, the second cracking product stream (572) is mixed or combined with the second portion of the LPG stream (524) and supplied to the ninth inlet of the olefin separation unit (580). The olefin separation unit (580) may include a tenth outlet that outputs an olefin stream (582) as a suitable chemical product. Thus, in certain embodiments, the system (500) utilizing the mixed feedstock steam cracker (570) and the mild hydrocracker (560) can increase the production of the chemical by about 50 to 70 weight percent.

[0061] The embodiments describe or illustrate selected aspects of various embodiments for producing chemicals and fuels from gas condensates using an improved FCC-based process. Those skilled in the art to which this disclosure pertains will come up with many modifications and other embodiments of this disclosure by taking advantage of the teachings set forth in the foregoing description and the related drawings. Accordingly, it should be understood that this disclosure is not limited to the specific embodiments disclosed herein and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms have been used in this specification, they are used only in a general and descriptive sense and are not intended to be limiting.

[0062] Examples

[0063] The following examples are presented to provide a complete disclosure and description to a person skilled in the art of how the compounds, compositions, articles, devices, and / or methods claimed herein are manufactured and evaluated; they are therefore intended to be purely illustrative and not intended to limit the disclosure. While efforts have been made to ensure accuracy regarding figures (e.g., quantities, temperatures, etc.), some deviations should be taken into account.

[0064] For example, there exist numerous variations and combinations of reaction conditions, such as component concentrations, desired solvents, solvent mixtures, temperature, pressure, and other reaction ranges and conditions, that can be used to optimize the product purity and yield obtained from the described process. Optimizing these process conditions will require only reasonable and conventional experiments.

[0065] Example 1. Typical characteristics of hydrocarbon condensate raw materials

[0066] The method and system disclosed herein implement a suitable hydrocarbon condensate stream as a feedstock for an improved yield of the desired product. For example, Table 1 shows the specific characteristics of three separate samples of hydrocarbon condensate.

[0067] Table 1: Physical properties of exemplary condensate raw materials

[0068]

[0069] Example 2. Composition of the steam cracker product stream

[0070] In certain embodiments, the method and system disclosed herein utilize a steam cracker or a mixed feedstock steam cracker to improve the yield of a desired chemical. For example, Table 2 shows examples of product flow / yield from said steam cracker for processing a condensate feedstock fraction having a boiling point of less than 185°C.

[0071] Table 2: Composition of steam cracker product effluent using oil feedstock below 185°C while recirculating alkane products

[0072]

[0073] Example 3. Composition of the catalytic decomposition product stream

[0074] As discussed above, the method and system disclosed herein may utilize a catalytic cracker for upgrading compounds in hydrocarbon condensates for an improved yield of desired chemicals and / or fuels. In certain embodiments, experiments may be performed to analyze the conversion rate and product yield distribution for a catalytic cracker supplied with a product stream containing a downer composition and having a boiling point of 350°C or higher. In some embodiments, the reaction temperature may be in the range of 600 to 675°C, the steam / oil ratio may be in the range of 0.1 to 0.5, and the catalyst-to-feed weight ratio may be 5 to 30. In this embodiment, the provided feedstock is a novel feedstock instead of a recycled feedstock. Table 3 shows examples of product compositions from a catalytic cracker having a reaction temperature of 675°C, a steam / oil ratio of 0.25, and a catalyst-to-feed weight ratio of 25.

[0075] Table 3: Composition of catalytic cracker product effluent using typical feedstock in the oil fraction range exceeding 350°C

[0076]

[0077] Other objects, features, and benefits of the present disclosure will become apparent from the foregoing drawings, detailed description, and examples. However, it should be understood that while the drawings, detailed description, and examples represent specific embodiments of the present disclosure, they are provided for illustrative purposes only and are not intended to be limiting. Additionally, changes and modifications within the spirit and scope of the present disclosure are to be considered to be apparent to a person skilled in the art from the detailed description. In additional embodiments, features of a specific embodiment may be combined with features of other embodiments. For example, features of one embodiment may be combined with features of any of the other embodiments. In additional embodiments, additional features may be added to the specific embodiments described herein.

Claims

Claim 1 As a method, A method comprising: providing a hydrocarbon condensate stream to a desalinator to produce a desalinated hydrocarbon condensate stream; providing the desalinated hydrocarbon condensate stream to a classifier to produce a first product stream and one or more second product streams, wherein the first product stream has a boiling point greater than about 350°C and the one or more second product streams each have a boiling point of about 350°C or less; providing the first product stream to a catalytic decomposer to produce a decomposition product stream; and recirculating the decomposition product stream to the classifier. Claim 2 A method according to claim 1, further comprising the step of providing at least one of the one or more second product streams to an olefin separation unit to produce an olefin-rich stream. Claim 3 In paragraph 1, A method further comprising the steps of: providing at least one of the above one or more second product streams to a steam decomposer to produce a second decomposition product stream; and providing the second decomposition product stream to an olefin separation unit to produce an olefin-rich stream. Claim 4 A method according to claim 2 or 3, wherein the olefin-rich stream comprises more than 50% by weight of ethene, propene, and butene. Claim 5 A method according to claim 1, further comprising the step of generating a gasoline stream from one or more second product streams. Claim 6 A method according to claim 5, further comprising the step of providing one of the above one or more second product streams to a catalytic reformer to produce a reformed product stream; and the step of supplying the reformed product stream to a gasoline blending unit to produce the gasoline stream. Claim 7 A method according to claim 1, further comprising the step of providing one of the one or more second product streams to a hydrocracker to generate a hydrocracker product stream; and the step of recirculating the hydrocracker product stream to the classifier. Claim 8 A method according to any one of claims 1 to 7, wherein the hydrocarbon condensate stream comprises a natural gas condensate having an American Petroleum Institute (API) specific gravity of about 45 to about 55. Claim 9 A system comprising: a desalinator configured to receive a hydrocarbon condensate stream and produce a desalinated hydrocarbon condensate stream; a classifier configured to receive the desalinated hydrocarbon condensate stream from the desalinator and produce a first product stream and one or more second product streams, wherein the first product stream has a boiling point greater than about 350°C and the one or more second product streams each have a boiling point less than about 350°C; and a catalytic decomposer configured to receive the first product stream, produce a decomposition product stream, and recirculate the decomposition product stream to the classifier. Claim 10 A system according to claim 9, further comprising an olefin separation unit configured to receive at least one of the one or more second product streams and to produce an olefin-rich stream. Claim 11 A system according to claim 9, further comprising: a steam decomposer configured to receive at least one of the one or more second product streams and to produce a second decomposition product stream; and an olefin separation unit configured to receive the second decomposition product stream and to produce an olefin-rich stream. Claim 12 A system according to claim 10 or 11, wherein the olefin-rich stream comprises more than 50% by weight of ethene, propene, and butene. Claim 13 A system according to claim 9, further comprising: a catalytic reformer configured to receive one of the one or more second product streams and produce a reformed product stream; and at least a gasoline blending unit configured to receive the reformed product stream and produce a gasoline stream. Claim 14 A system according to claim 9, further comprising a hydrocracker configured to receive one of the one or more second product streams, generate a hydrocracking product stream, and recirculate the hydrocracking product stream to the classifier. Claim 15 A system according to any one of claims 9 through 14, wherein the hydrocarbon condensate stream has an American Petroleum Institute (API) specific gravity of about 45 to about 55.

Images