Methods and systems for producing chemicals and fuels from condensates using fluid catalytic cracking processes

Abstract

The disclosure provides methods and systems for producing chemicals and fuels from condensates using fluid catalytic cracking processes. In an embodiment, a method can include providing a hydrocarbon condensate stream to a desalter to produce a desalted hydrocarbon condensate stream; providing the desalted hydrocarbon condensate stream to a fractionator to produce a first product stream and one or more second product streams, where the first product stream includes a boiling point that is greater than about 350 °C and the one or more second product streams each include a boiling point that is less than or equal to about 350 °C; providing the first product stream to a catalytic cracker to produce a cracked product stream; and recycling the cracked product stream to the fractionator.

Description

METHODS AND SYSTEMS FOR PRODUCING CHEMICALS AND FUELS FROM CONDENSATES USING FLUID CATALYTIC CRACKING PROCESSESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of European Application No. EP23220272.1, filed on December 27, 2023. The contents of the referenced application are incorporated into the present application by reference.TECHNICAL FIELD

[0002] The present disclosure generally relates to methods and systems for producing chemicals and fuels from condensates using fluid catalytic cracking processes.BACKGROUND

[0003] Condensate, or natural gas condensate, is a hydrocarbon liquid stream having low-density compounds that are gaseous in their raw state within natural gas fields and condensable into liquid when separated from lighter, raw natural gas. Condensate is a common by-product of both gas and oil production. Globally, the production of condensates has been steadily increasing over recent decades and this trend is expected to continue. As such, it would be beneficial to maximize the use of condensates to produce more valuable products whenever possible.

[0004] Certain high-value chemicals and fuels are typically manufactured by thermal cracking of ethane, propane, butane, and naphtha. For example, around half of all produced ethene is generated by thermal cracking processes. In addition, these products may be produced through conversion of heavy feedstocks such as gas oils or residues with refinery fluidized catalytic cracking (FCC) processes. However, as demands rise for these basic intermediate compounds, a corresponding demand is increasing for exploration of other production sources, beyond traditional thermal cracking processes or FCC processes.SUMMARY

[0005] To address the above issues, embodiments disclosed herein include methods and systems for producing chemicals and fuels from condensates using improved FCC-based processes. In certain embodiments, the condensates used as feedstock to produce chemicals and fuels include an American Petroleum Institute (API) gravity range from about 45-55. The embodiments disclosed herein can provide higher yield of desired products compared to any existing condensate-based refinery processes, with minimum additional equipment. For example, desired chemical and / or fuel products can be produced with one or more system configurations disclosed herein, which enable maximization of product yield, without excessive increases in capital costs.

[0006] As an example, certain embodiments of these systems include a desalter, a fractionator, and a catalytic cracker. The desalter removes salt, sand, mud, and sediments from a condensate stream to produce a desalted condensate stream, which is supplied to the fractionator. The fractionator thus separates the desalted condensate stream into various fractions, including a heavy product stream that is supplied to the catalytic cracker. The catalytic cracker is operated to crack the heavy product stream into a cracked product stream that is recycled to the fractionator. As such, from a top thereof, the fractionator can output fuel gas as well as supply liquid petroleum gas (LPG) to an olefins separation unit. From a first side outlet of the fractionator, a naphtha product stream can be supplied to a gasoline preparation unit. Additionally, from a second side outlet of the fractionator, a diesel stream is split to supply a first portion as a diesel blendstock and supply a second portion to be combined with the heavy product stream supplied to the catalytic cracker. Recycling the heavy product stream and the second portion of the diesel stream thus provides for enhanced production of light olefins from the olefins separation unit and enhanced production of gasoline from the gasoline preparation unit.

[0007] As another example, in certain embodiments, the systems disclosed herein include a desalter, a fractionator, a catalytic cracker, and a catalytic reformer. The desalter removes salt, sand, mud, and sediments from a condensate stream to produce a desalted condensate stream, which is supplied to the fractionator. The fractionator separates the desalted condensate stream into multiple streams, including a heavy product stream supplied from a bottom of the fractionator to the catalytic cracker. The fractionator can also separate light products including fuel gas and LPG from a top of the fractionator, and direct the LPG to an olefins separation unit. As side draws, the fractionator can output a naphtha product stream, a light cycle oil stream, and a heavy cycle oil stream. The fractionator therefore directs the heavy cycle oil, having a higher boiling point than the light cycle oil stream, to be combined with the heavy product stream that is supplied to the catalytic cracker. The fractionator can supply a first portion of the naphtha product stream to a gasoline preparation unit and supply a second portion of the naphtha product stream to the catalytic reformer. The light cycle oil stream is also directed to the catalytic reformer along with the second portion of the naphtha stream. The catalytic reformer thus produces a reformed product stream thatis supplied to the gasoline preparation unit. As such, recycling the heavy product stream and the heavy cycle oil, as well as implementing the catalytic reformer, creates enhanced production of light olefins from the olefins separation unit and enhanced production of gasoline from the gasoline preparation unit.

[0008] As an additional example, in certain embodiments, the systems disclosed herein include a desalter, a fractionator, a catalytic cracker, and a steam cracker. The desalter, the fractionator, and the catalytic cracker can generally operate as discussed above with reference to the systems having a desalter, a fractionator, and a catalytic cracker. Instead of a gasoline preparation unit, a naphtha product stream from a first side outlet of the fractionator is supplied to the steam cracker. The steam cracker can also receive all or a portion of LPG supplied from a top of the fractionator. As such, the steam cracker produces a second cracked product stream that is directed to an olefins separation unit. Additionally, the olefins separation unit can directly receive all or a remaining portion of the LPG supplied from the fractionator. The recycling of a heavy product stream with the catalytic cracker combined with the conversion or upgrading of the steam cracker thus drives the production of chemicals, such as light olefins, from the olefins separation unit to desirably increase chemical yields.

[0009] As a further example, in certain embodiments, the systems disclosed herein include a desalter, a fractionator, a catalytic cracker, a steam cracker, and a hydrocracker. The desalter, the fractionator, the catalytic cracker, and the steam cracker can generally operate as discussed above with reference to the systems having a desalter, a fractionator, a catalytic cracker, and a steam cracker. However, the fractionator can also separate and output a heavy cycle oil stream, of which a first portion is recycled with the heavy product stream to the catalytic cracker. The fractionator further separates and outputs a light cycle oil stream, which is mixed or combined with the second portion of the heavy cycle oil stream and supplied to the hydrocracker. Using a supply of hydrogen, the hydrocracker can produce a hydrocracked product stream that is recycled to the fractionator. Certain systems therefore include a first recycling loop for heavy-range fractions directed to the catalytic cracker, a second recycling loop for middle-range fractions directed to the hydrocracker, as well as a steam cracker to further upgrade light-range components. These processes therefore interoperate or cooperate to provide improved production and yield of light olefins from the olefins separation unit.

[0010] Accordingly, embodiments disclosed herein include methods for producing chemical and / or fuel products with enhanced yield. One such method includes providing a hydrocarbon condensate stream to a desalter to produce a desalted hydrocarbon condensate stream and providing the desalted hydrocarbon condensate stream to a fractionator to produce a first product stream and one or more second product streams. The first product stream includes a boiling point that is greater than about 350 °C and the one or more second product streams each include a boiling point that is less than or equal to about 350 °C. The method further includes providing the first product stream to a catalytic cracker to produce a cracked product stream and recycling the cracked product stream to the fractionator.

[0011] In some embodiments, the method further includes providing at least one of the one or more second product streams to an olefins separation unit to produce an olefins-rich stream. In some embodiments, the method further includes providing at least one of the one or more second product streams to a steam cracker to produce a second cracked product stream and providing the second cracked product stream to an olefins separation unit to produce an olefins-rich stream. In some embodiments, the olefins-rich stream includes more than 50 wt.% of ethene, propene, and butenes.

[0012] In some embodiments, the method further includes producing a gasoline stream from the one or more second product streams. In some embodiments, the method further includes providing one of the one or more second product streams to a catalytic reformer to produce a reformed product stream and supplying the reformed product stream to a gasoline blending unit to produce the gasoline stream. In some embodiments, the method further includes providing one of the one or more second product streams to a hydrocracker to produce a hydrocracked product stream and recycling the hydrocracked product stream to the fractionator. In some embodiments, the hydrocarbon condensate stream includes natural gas condensate having an American Petroleum Institute (API) gravity of about 45 to about 55.

[0013] Additionally, embodiments disclosed herein include systems for producing chemical and / or fuel products with enhanced yield. One such system includes a desalter configured to receive a hydrocarbon condensate stream and produce a desalted hydrocarbon condensate stream. The system further includes a fractionator configured to receive the desalted hydrocarbon condensate stream from the desalter and produce a first product stream and one or more second product streams. The first product stream has a boiling point that is greater than about 350 °C andthe one or more second product streams each have a boiling point that is less than or equal to about 350 °C. The system further includes a catalytic cracker configured to receive the first product stream, produce a cracked product stream, and recycle the cracked product stream to the fractionator.

[0014] In some embodiments, the system further includes an olefins separation unit configured to receive at least one of the one or more second product streams and produce an olefins-rich stream. In some embodiments, the system further includes a steam cracker configured to receive at least one of the one or more second product streams and produce a second cracked product stream and an olefins separation unit configured to receive the second cracked product stream and produce an olefins-rich stream. In some embodiments, the olefins-rich stream includes more than 50 wt.% of ethene, propene, and butenes.

[0015] In some embodiments, the system further includes 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 includes a hydrocracker configured to receive one of the one or more second product streams, produce a hydrocracked product stream, and recycle the hydrocracked product stream to the fractionator. In some embodiments, the hydrocarbon condensate stream has an API gravity of about 45 to about 55.

[0016] Aspects and advantages of these exemplary embodiments and other embodiments, are discussed in detail herein. Moreover, it is to be understood that both the foregoing information and the following detailed description provide merely illustrative examples of various aspects and embodiments, and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. Accordingly, these and other objects, along with advantages and features of the present disclosure, will become apparent through reference to the following description and the accompanying drawings. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and may exist in various combinations and permutations.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of thisspecification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the various ways in which they may be practiced. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to illustrate embodiments of the disclosure more clearly.

[0018] FIG. 1 is a block diagram of an embodiment of a method of producing chemicals and fuels from condensates, according to an embodiment of the present disclosure.

[0019] FIG. 2 is diagrammatic representation of a system with a desalter, a fractionator, and a catalytic cracker, according to an embodiment of the present disclosure.

[0020] FIG. 3 is diagrammatic representation of a system with a desalter, a fractionator, a catalytic cracker, and a catalytic reformer, according to an embodiment of the present disclosure.

[0021] FIG. 4 is diagrammatic representation of a system with a desalter, a fractionator, a catalytic cracker, and a steam cracker, according to an embodiment of the present disclosure.

[0022] FIG. 5 is diagrammatic representation of a system with a desalter, a fractionator, a catalytic cracker, a steam cracker, and a hydrocracker, according to an embodiment of the present disclosure.DETAILED DESCRIPTION

[0023] The present disclosure describes various embodiments related to methods and systems for producing chemicals and fuels from condensates, such as by implementing catalytic cracking processes integrated with pretreating and other upgrading processes. As discussed above, there is an increasing demand for utilizing condensates more effectively for fuel and chemical production. Thus far, many researchers have been investigating the use of condensates for blending with conventional crude oil in refinery processes. For example, the availability of pretreating, hydrotreating, and hydrocracking equipment may contribute to the regularity by which condensate is used in this manner, which is limited to less than its full potential. In some cases, the majority of products produced by the blending of condensate with conventional crude oil includes naphtha range components, such as C5+ products. However, various significant changes, such as modified process conditions, equipment redesign, and / or variation in catalyst type or composition, may berequired to achieve higher chemical yields than previously available via blending of condensate into crude, followed by further processing steps, to produce chemicals.

[0024] As disclosed herein, various embodiments of the present disclosure produce chemicals and fuels from condensates at improved yields and efficiencies. In general, certain embodiments disclosed herein include desalting a hydrocarbon condensate stream and fractionating the desalted hydrocarbon condensate stream to produce (1) one or more lighter streams that then are used to produce olefins and / or fuels and (2) a heavy stream that is recycled to the fractionator after catalytic cracking. In certain embodiments, the one or more lighter streams include any suitable streams disclosed herein, including a heavy cycle oil stream, a light cycle 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 multiple configurations, each of which is suitable for converting a condensate-based feedstock to produce high value chemicals such as light olefins and aromatics. The products can be efficiently manufactured based on providing a desalted hydrocarbon stream to a fractionator and recycling a heavy or bottom stream therefrom to a catalytic cracker and back to the fractionator. Certain embodiments include implementing the catalytic cracker as a central unit in a fluid catalytic cracking process.

[0025] In more detail, a condensate feedstock is desalted in a suitable desalter to prepare the condensate for further processing, such as by removing salt, sand, mud, and / or sediment. In some embodiments, the condensates include a range of hydrocarbons, such as those that contain three or more carbon atoms to those boiling at over 565 °C. In some embodiments, the condensates have an API gravity range from 45-55. Once desalted and / or decontaminated, the condensate feedstock is supplied to and processed in a fractionator or fractionating column. The fractionator produces fractionated cuts, based on the product specifications, that can be further processed in a catalytic cracker (having a riser or a downer configuration), reformer unit, and / or hydrocracker unit. Indeed, the present embodiments include various combinations of equipment, such as the catalytic cracker with or without the reformer unit and with or without the hydrocracker unit. In addition, certain embodiments also include integration with a steam cracker or mixed feed steam cracker to further increase the production of light olefins and aromatics.

[0026] Accordingly, the present disclosure addresses multiple challenges previously faced in the industry. For example, certain embodiments provide for use of condensates to produce chemicals and fuels utilizing a minimum number of process units, while maximizing the selectivity for highvalue products. In certain embodiments, a process configuration is implemented that maximizes production of fuels from condensate, while also producing chemicals. Additionally, in certain embodiments, a process configuration is implemented that maximizes production of chemicals from condensate. For example, certain embodiments include processing condensate feedstock in combination with fluid catalytic cracking integrated with downstream units, such as a fractionation unit, without reliance on many additional separation units. In some embodiments, an improved or optimal ratio of rare earth modified USY catalyst and ZSM-5 based additive is provided to achieve maximum production of chemicals and fuels in the catalytic cracker.

[0027] Further embodiments may be described and disclosed. In the following description, numerous details are set forth in order to provide a thorough understanding of the various embodiments. In other instances, well-known processes, devices, and systems may not have been described in particular detail in order not to unnecessarily obscure the various embodiments. Additionally, illustrations of the various embodiments may omit certain features or details in order to not obscure the various embodiments.

[0028] The description may use the phrases “in certain embodiments,” “in various embodiments,” “in an embodiment,” or “in embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous. The term “about” refers to a range of values including the specified value, which a person of ordinary skill in the art would consider reasonably similar to the specified value. In embodiments, “about” refers to values within a standard deviation using measurements generally acceptable in the art. In one non-limiting embodiment, when the term “about” is used with a particular value, then “about” refers to a range extending to ±10% of the specified value, alternatively ±5% of the specified value, or alternatively ±1% of the specified value, or alternatively ±0.5% of the specified value. In embodiments, “about” refers to the specified value.

[0029] The terms “removing,” “removed,” “reducing,” “reduced,” or any variation thereof, when used in the claims and / or the specification includes any measurable decrease of one or more components in a mixture to achieve a desired result. The use of the words “a” or “an” when used in conjunction with any of the terms “comprising,” “including,” “containing,” or “having,” in the claims or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The term “plurality” as used herein refers totwo or more items or components. The terms “wt.%”, “vol.%”, or “mol.%” refers to a weight, volume, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, that includes the component. In a non-limiting example, 10 grams of component in 100 grams of the material is 10 wt.% of component.

[0030] Embodiments of methods, systems, and compositions described here are utilized to improve production of chemicals and fuels from condensates using fluid catalytic cracking processes. In certain embodiments, a method includes providing a hydrocarbon condensate stream to a desalter to produce a desalted hydrocarbon condensate stream and providing the desalted hydrocarbon condensate stream to a fractionator to produce a first product stream (or heavy stream) and one or more second product streams (or light streams). The first product stream can have a boiling point that is greater than about 350 °C and the one or more second product streams can each have a boiling point that is less than or equal to about 350 °C. The method includes providing the first product stream to a catalytic cracker to produce a cracked product stream and recycling the cracked product stream to the fractionator.

[0031] Disclosed embodiments also include methods for producing chemicals and fuels from condensates using fluid catalytic cracking processes. FIG. l is a block diagram of an embodiment of a method 100 to produce at least an olefins-rich stream, based on conversion and / or upgrading of a hydrocarbon condensate stream. In some embodiments, the method 100 can generally correspond to certain embodiments of the elements and systems discussed with reference to FIGS. 2-5. The method includes the step 102 of providing a hydrocarbon condensate stream to a desalter. In some embodiments, the hydrocarbon condensate stream can include an API gravity of about 45 to about 55. Additionally, by removing salts that can otherwise contaminate or negatively affect operation, desalting of the hydrocarbon condensate stream generally increases an efficiency and / or yield of products produced via the method 100. In some examples, the desalter removes additional materials or contaminants such as sand, mud, and / or sediments. The method includes the step 104 of providing the desalted hydrocarbon condensate stream to a fractionator to produce a first product stream and one or more second product streams. The first product stream includes a boiling point that is greater than about 350 °C and the one or more second product streams each include a boiling point that is less than or equal to about 350 °C. As discussed above, the first product stream can correspond to a heavy product stream. Additionally, the one or more second product streams can include any suitable one or combination of other streams discussed above, such as a heavy cycleoil stream, a light cycle oil stream, a diesel product stream, a naphtha product stream, a fuel gas stream, an LPG stream, or any combination thereof. The method includes the step 106 of providing the first product stream to a catalytic cracker to produce a cracked product stream and the step 108 of recycling the cracked product stream to the fractionator.

[0032] Additionally, the method includes the step 110 of providing at least one of the one or more second product streams to an olefins separation unit to produce an olefins-rich stream. The olefins-rich stream can include more than 50 wt.% of ethene (or ethylene), propene (or propylene), and butenes. The method can further include additional steps to increase or improve a yield of olefins and high-value chemicals. For example, in some embodiments, the method further includes providing at least one of the one or more second product streams to a steam cracker to produce a second cracked product stream, and providing the second cracked product stream to the olefins separation unit. Non-limiting examples of steam crackers are shown as 470 and 570 in FIGS. 4 and 5, respectively. In some of these embodiments, the method includes providing one of the one or more second product streams to a hydrocracker to produce a hydrocracked product stream and recycling the hydrocracked product stream to the fractionator, such as the mild hydrocracker 560 in FIG. 5

[0033] In some embodiments, the method further includes producing a gasoline stream from the one or more second product streams. In some of these embodiments, the method includes providing one of the one or more second product streams to a catalytic reformer to produce a reformed product stream, and supplying the reformed product stream to a gasoline blending unit to produce the gasoline stream. Non-limiting examples that include gasoline production are shown in FIGS. 2 and 3.

[0034] FIG. 2 is a diagrammatic representation of a system 200 for producing chemicals and fuel from condensate via a desalter, a fractionator, and a catalytic cracker, according to an embodiment of the present disclosure. In certain embodiments, the system 200 increases a yield of desired products, without overly increasing a capex for the system 200. The system 200 includes various operational units arranged in a suitable configuration for processing a condensate stream 202, hydrocarbon condensate feedstock, or crude condensate. Certain embodiments of the condensate stream 202 include a feedstock having an API gravity range from 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 otherminerals. For instance, certain condensate streams 202 include a salt concentration in a range of 1-15 Pounds per Thousand Barrel (PTB).

[0035] The system 200 includes a desalter 204 having a first inlet to receive the condensate stream 202 and having a first outlet to output a desalted condensate stream 206. The desalter 204 can remove salts from the condensate stream 202 via any suitable process to refine the condensate stream 202 for further upgrading. For example, the desalter 204 can include a tank or mixer into which the condensate stream 202 and a fresh or treated water stream are mixed to provide a homogeneous or uniform mixture. In certain embodiments, the uniform mixture is heated to a temperature near to the boiling point of the condensate stream 202, such as 78-80 °C. That is, certain embodiments of the desalter 204 heat the uniform mixture to an initial boiling point temperature, thereby maintaining the uniform mixture in a liquid state. Within the uniform mixture, water soluble salts generally transfer from an organic phase corresponding to the condensate stream 202 to an aqueous phase corresponding to the water stream. The desalting process can remove a majority of the salts from the organic phase. In some embodiments, the organic phase is desalted to a salt concentration of less than 1 PTB. The desalter 204 can perform a single stage or a double stage desalting process to achieve a target salt concentration in the organic phase, in certain embodiments.

[0036] After mixing and heating, the organic phase and aqueous phase can be transferred to a settler tank of the desalter 204, in which the phases are separated. In some embodiments, the desalter 204 includes electrical devices and / or chemical additives to facilitate separation of the organic phase and the aqueous phase. The organic phase can thus be output by the desalter 204 as the desalted condensate stream 206. Removal of salts from the condensate stream 202 desirably increases an efficiency and / or yield of products produced by the system 200, including chemical and / or fuel products. Depending on the source or location from which the condensate stream 202 originated, the condensate stream 202 can also contain other impurities, such as nitrogen and / or sulfur compounds. As such, certain embodiments of the system 200 additionally include a hydrotreater to hydrotreat the condensate stream 202 based on the content of other impurities therein. Certain examples of the desalter 204 can also remove sand, mud, and / or sediments that are present in the condensate stream 202.

[0037] As illustrated, the system 200 includes a fractionator 210 having a second inlet to receive the desalted condensate stream 206 from the desalter 204. In certain embodiments, the fractionator210 includes a preheater to raise the temperature of the desalted condensate stream 206 before fractionating. The fractionator 210 is or include a fractionating column that separates the desalted condensate stream 206 into various fractions, streams, and / or products. The fractionating column can include any suitable arrangement of packing and / or trays to facilitate separation of the products therein. The illustrated embodiment of the fractionator 210 includes (i) a second outlet or bottom outlet to output a heavy product stream 212 or bottom end fraction, (ii) a third outlet or first side outlet to output a diesel product stream 214, (iii) a fourth outlet or second side outlet to output a naphtha product stream 220, and (iv) a fifth outlet or top outlet to output a top product stream or light end fraction including a fuel gas stream 222 and an LPG stream 224. It should be understood that the specific arrangement of inlets and outlets for the fractionator 210 and other equipment is provided as an illustrative example, which is non-limiting and can be adjusted based on any suitable process characteristics.

[0038] A catalytic cracker 230 or fluid catalytic cracker is provided in the system 200 to increase fuel and chemical yield from the desalted condensate stream 206, in certain embodiments. As the heaviest fraction, the heavy product stream 212 includes the highest boiling point and is directed from the second outlet of the fractionator 210 and to a third inlet of the catalytic cracker 230. In some embodiments, the heavy product stream 212 includes a boiling point that is higher than 350 °C. The heavy product stream 212 contains slurry oil and / or atmosphere residue, in certain embodiments. The system 200 can supply the heavy product stream 212 to the catalytic cracker 230 as fresh feed thereto, along a recycle loop within the system 200. As such, any high molecular weight compounds in streams provided to the catalytic cracker 230, such as those present in the heavy product stream 212, can be recycled into extinction to produce more valuable products.

[0039] In some embodiments, the catalytic cracker 230 cracks the heavy product stream 212 to convert the heavy product stream 212 into a cracked product stream 232. The catalytic cracker 230 can include a sixth outlet to output the cracked product stream 232 and supply the cracked product stream 232 into a fourth inlet of the fractionator 210, in some embodiments. As such, the cracked product stream 232 can be recycled or fed back to the fractionator 210 to yield the different fractions or products disclosed herein, including chemicals and fuels. In some embodiments, the catalytic cracker 230 also outputs a flue gas 234 that is generated during the cracking process. The catalytic cracker 230 of certain embodiments yields about 20-40% of light olefins, such as ethene,propene, and butenes. In some embodiments, the catalytic cracker 230 and the fractionator 210 operate together as an integrated processing unit, such as a fluid catalytic cracking complex.

[0040] Looking to progressively lighter fractions produced by the fractionator 210, the diesel product stream 214 can be output from the third outlet of the fractionator 210 as a fraction containing middle distillate range components. In some embodiments, the diesel product stream 214 includes cycle oil having a boiling point that ranges between 185-350 °C. The diesel product stream 214 can be split into two portions, such as a first portion that is combined with the heavy product stream 212 recycled to the catalytic cracker 230. In certain embodiments, a second portion of the diesel product stream 214 is provided from the system 200 as a diesel blendstock 215. The diesel blendstock 215 can correspond to a suitable fuel product, in certain embodiments.

[0041] The naphtha product stream 220 can be output from the fourth outlet of the fractionator 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 represents about a 30-40 wt.% yield of the naphtha / liquid, such as based on naphtha-rich content of the condensate stream 202 and / or the cracked product stream 232. The naphtha product stream 220 is supplied to a fifth inlet of a gasoline preparation unit 276 or refinery gasoline pool, in some embodiments. The gasoline preparation unit 276 can produce and output a gasoline stream 278 or product, which is output from a seventh outlet of the gasoline preparation unit 276. The gasoline stream 278 can be transported from the system 200 as a suitable fuel product, in certain embodiments.

[0042] Output from the fifth outlet of the fractionator 210, the top product stream of the fractionator 210 contains fuel gas 222 and / or LPG 224. For example, in certain embodiments, the top product stream contains hydrogen, methane, ethane, ethene, propane, propene, butanes, and / or butenes. The top product stream can generally include compounds that remain in a gaseous state under conditions within the fractionator 210, such as compounds associated with fuel gas and / or LPG. In certain embodiments, the top product stream provides about 5-20 wt.% of total output from the fractionator 210. In some embodiments, the system 200 includes a separation vessel or splitter to separate the fuel gas stream 222 from the LPG stream 224, each provided from the fifth outlet of the fractionator 210. The fuel gas stream 222 can be transported from the system 200 as a suitable fuel product, in certain embodiments.

[0043] In some embodiments, the LPG stream 224 generally includes a high content of light olefins, such as propene. The LPG stream 224 of certain embodiments can be supplied to a sixth inlet of an olefins separation unit 280, which includes an eighth outlet to output an olefins stream 282 or light olefins stream therefrom. As should be understood, the disclosed embodiments of the system 200 produce the light olefins at a desirably increased yield, compared to previously available systems without the present configuration of the catalytic cracker 230. Additionally, the system 200 can generally provide an overall yield of fuels that is about 40-60 wt.%, in some embodiments. In some embodiments, the system 200 produces a minimum recovery or lower threshold recovery of about 35 to 45 wt.% fuels. Additionally, fuels can be directly separated from the desalted condensate stream 206, thus reducing capex of the system 200 compared to systems that rely upon additional separation equipment.

[0044] FIG. 3 is a diagrammatic representation of a system 300 for producing chemicals and fuel from condensate via a desalter, a fractionator, a catalytic cracker, and a catalytic reformer, according to an embodiment of the present disclosure. In certain embodiments, the system 300 increases a yield of desired products via catalytic reforming, which upgrades compounds associated with diesel or certain light cycle oil into gasoline. The system 300 includes certain operational units that correspond to those discussed above with reference to FIG. 2. For enhanced clarity, the description of certain operational units is not repeated in detail here.

[0045] The system 300 processes a condensate stream 302 into desired fuels and chemicals. In certain embodiments, the condensate stream 302 is supplied to a first inlet of a desalter 304. The desalter can operate or be operable to remove salts from the condensate stream 302 and output a desalted condensate stream 306 via a first outlet of the desalter 304. The desalted condensate stream 306 is thus supplied to a second inlet of a fractionator 310. The fractionator 310 can separate the products therein based on their boiling points. For example, in some embodiments, the fractionator 310 includes (i) a second outlet that outputs a heavy product stream 312, (ii) a third outlet that outputs a heavy cycle oil stream 316, (iii) a fourth outlet that outputs a light cycle oil stream 318, (iv) a fifth outlet that outputs a naphtha product stream 320, and (v) a sixth outlet that outputs a top product stream.

[0046] As previously described, the heavy product stream 312 is supplied from the second outlet of the fractionator 310 and into a third inlet of a catalytic cracker 330. In some embodiments, the heavy product stream 312 has a boiling point higher than 350 °C. In some embodiments, thecatalytic cracker 330 cracks the heavy product stream 312 into a cracked product stream 332, which is supplied out of a seventh outlet of the catalytic cracker 330 and into a fourth inlet of the fractionator 310. The catalytic cracker 330 can also output a flue gas 334. The heavy cycle oil stream 316 is combined with the heavy product stream 312 and recycled to the catalytic cracker 330, in certain embodiments. In certain embodiments, the heavy cycle oil stream 316 includes a boiling point ranging from 225-350 °C.

[0047] As discussed above, the top product stream from the fractionator 310 can include fuel gas and / or LPG. A fuel gas stream 322 is separated from the top product stream and provided as a suitable fuel product, in some embodiments. Additionally, an LPG stream 324 can be separated from the top product stream and directed into a fifth inlet of an olefins separation unit 380. In some embodiments, the olefins separation unit 380 includes an eighth outlet that outputs an olefins stream 382 as a suitable chemical product.

[0048] In the illustrated embodiment, the light cycle oil stream 318 and the naphtha product stream 320 are be utilized for production of gasoline. For example, the naphtha product stream 320 can be split into two portions, including a first portion that is supplied to a sixth inlet of a catalytic reformer 350 and a second portion that is supplied to a seventh inlet of a gasoline preparation unit 376. In certain embodiments, the naphtha product stream 320 represents about a 30-40 wt.% yield of naphtha / liquid, such as based on naphtha-rich content of the condensate stream 302 and / or the cracked product stream 332. Additionally, the light cycle oil stream 318 can be combined with the first portion of the naphtha product stream 320 that is directed into the catalytic reformer 350. In certain embodiments, the light cycle oil stream 318 includes a boiling point ranging from 185-225 °C.

[0049] The catalytic reformer 350 is operable to convert or upgrade the light cycle oil stream 318 and the first portion of the naphtha product stream 320 into a reformed product stream 352, in certain embodiments. For example, the catalytic reformer 350 can increase an octane number of the compounds therein, such as by utilizing hydrogenation-dehydrogenation catalysts with a fixed bed reactor in the presence of hydrogen. That is, catalytic reforming converts low-octane effluent stream into high-octane aromatic hydrocarbons, in some embodiments. In certain embodiments, the catalytic reformer 350 operates at reaction temperatures between 450 and 520 °C and at reaction pressures between 5 to 45 atm. In some embodiments, the catalytic reformer includes a hydrogen-to-hydrocarbon molar ratio ranging from 3 to 8. The catalyst utilized in the catalyticreformer 350 can be supported on alumina and can contain any suitable noble metals such as chlorinated platinum, palladium promoted with tin, tungsten, nickel, rhodium, and / or cobalt supported on alumina, in some embodiments.

[0050] The catalytic reformer 350 includes a ninth outlet that outputs the reformed product stream 352. In some embodiments, the reformed product stream 352 is supplied into an eighth inlet of the gasoline preparation unit 376. As such, the gasoline preparation unit 376 can utilize both the reformed product stream 352 and the second portion of the naphtha product stream 320 to produce a gasoline stream 378. The gasoline stream 378 is output from the gasoline preparation unit 376 via a tenth outlet as a suitable fuel product, in certain embodiments. In certain embodiments, inclusion of the catalytic reformer 350 further increases total fuel production up to about 50 to 70 wt.% for the system 300.

[0051] FIG. 4 is a diagrammatic representation of a system 400 for producing chemicals and fuel from condensate via a desalter, a fractionator, a catalytic cracker, and a steam cracker, according to an embodiment of the present disclosure. In certain embodiments, the system 400 increases production of chemicals based on integration with the steam cracker. The system 400 includes certain operational units that correspond to those discussed above with reference to FIG. 2. For enhanced clarity, the description of certain operational units is not repeated in detail here.

[0052] The system 400 can generally process a condensate stream 402 into desired products, which include an increased yield of chemicals. In certain embodiments, the condensate stream 402 is supplied to a first inlet of a desalter 404, which removes salts from the condensate stream 402 and outputs a desalted condensate stream 406 via a first outlet of the desalter 404. The desalted condensate stream 406 can be supplied to a second inlet of a fractionator 410. The fractionator 410 therefore separates the products or compounds therein based on their respective boiling points. For example, in some embodiments, the fractionator 410 includes (i) a second outlet that outputs a heavy product stream 412, (ii) a third outlet that outputs a diesel product stream 414 or cycle oil stream, (iii) a fourth outlet that outputs a naphtha product stream 420, and (iv) a fifth outlet that outputs a top product stream including a fuel gas stream 422 and an LPG stream 424.

[0053] As previously described, the heavy product stream 412 is supplied from the second outlet of the fractionator 410 and into a third inlet of a catalytic cracker 430, which cracks the heavy product stream 412 into a cracked product stream 432. The catalytic cracker 430 can also output a flue gas 434. The system 400 can supply the cracked product stream 432 from a seventh outlet ofthe catalytic cracker 430 and into a fourth inlet of the fractionator 410. In certain embodiments, the diesel product stream 414 is output from the third outlet of the fractionator 410 as a fraction containing middle distillate range components. The diesel product stream 414 of certain embodiments is split into two portions, such as a first portion that is combined with the heavy product stream 412 recycled to the catalytic cracker 430. In certain embodiments, a second portion of the diesel product stream 414 is provided from the system 400 as a diesel blendstock 415. The diesel blendstock 415 can correspond to a suitable fuel product, in certain embodiments.

[0054] In certain embodiments, all or a portion of the naphtha product stream 420 is be utilized for production of chemicals, instead of gasoline. In some embodiments, the naphtha product stream 420 corresponds to about 30-45 wt.% of the total product from fractionator 410. The naphtha product stream 420 is output from the fourth outlet of the fractionator 410, with a first portion of the naphtha product stream 420 supplied to a fifth inlet of a mixed feed steam cracker 470 or 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 a naphtha blendstock 421, in certain embodiments. In some embodiments, the top product stream from the fractionator 410 includes fuel gas and / or LPG. A fuel gas stream 422 is be separated from the top product stream and provided as a suitable fuel product, in some embodiments. Additionally, an LPG stream 424 can be separated from the top product stream, where a first portion of the LPG stream 424 is directed into a sixth inlet of the mixed feed steam cracker 470.

[0055] The mixed feed steam cracker 470 is operable to crack the first portion of the LPG stream 424 and the first portion of the naphtha product stream 420 to produce a second cracked product stream 472. The mixed feed steam cracker 470 can process the compounds therein at high temperature to convert lighter fraction / naphtha range components into more useful or higher value products. In certain embodiments, the mixed feed steam cracker 470 operates with a variety of propene to ethene weight ratio, which ranges between 0.4 to 0.6 in the outlet product mixture. The outlet temperature of the mixed feed steam cracker 470 is in the range of 800-850 °C, in certain embodiments. Additionally, the operating pressure of the mixed feed steam cracker 470 is maintained slightly above atmospheric pressure, such as within 1%, 3%, or 5% of atmospheric pressure, in some embodiments.

[0056] The second cracked product stream 472 produced by the mixed feed steam cracker 470 can include a range of products. In some embodiments, the products of the second cracked productstream 472 include ethene, propene, aromatics (such as benzene, toluene, xylenes, ethylbenzene, styrene, and more), hydrogen, methane, carbon monoxide, carbon dioxide, heavier organic components, and other organic components. Certain light compounds formed in the mixed feed steam cracker 470, including products or alkanes such as ethane, propane, butanes, pentanes, can be fed back to the mixed feed steam cracker 470 as a recycle feedstock, in certain embodiments. In some embodiments, the mixed feed steam cracker 470 includes a seventh outlet that outputs the second cracked product stream 472.

[0057] The second cracked product stream 472 can be mixed or combined with the second portion of the LPG stream 424 and supplied into a seventh inlet of an olefins separation unit 480. The olefins separation unit 480 can include an eighth outlet that outputs an olefins stream 482 as a suitable chemical product, with increased yield of chemicals compared to systems without the mixed feed steam cracker 470. Indeed, in addition to separation of fuels from the treated condensate by the fractionator 410, the system 400 utilizing the mixed feed steam cracker 470 can increase production of chemicals by around 30-50 wt.%.

[0058] FIG. 5 is a diagrammatic representation of a system 500 for producing chemicals and fuel from condensate via a desalter, a fractionator, a catalytic cracker, a steam cracker, and a hydrocracker, according to an embodiment of the present disclosure. In certain embodiments, the system 500 increases production of chemicals based on integration with the steam cracker and the hydrocracker. The system 500 includes certain operational units that correspond to those discussed above with reference to FIG. 4. For enhanced clarity, the description of certain operational units is not repeated in detail here.

[0059] The system 500 processes a condensate stream 502 into desired products, with an increased yield of chemicals. In certain embodiments, the condensate stream 502 is supplied to a first inlet of a desalter 504, which removes salts from the condensate stream 502 and outputs a desalted condensate stream 506 via a first outlet of the desalter 504. The desalted condensate stream 506 is supplied to a second inlet of a fractionator 510, which separates the products therein based on their boiling points. For example, in some embodiments, the fractionator 510 includes (i) a second outlet that outputs a heavy product stream 512, (ii) a third outlet that outputs a heavy cycle oil stream 516, (iii) a fourth outlet that outputs a light cycle oil stream 518, (iv) a fifth outlet that outputs a naphtha product stream 520, and (v) a sixth outlet that outputs a top product stream.

[0060] The heavy product stream 512 can be supplied from the second outlet of the fractionator 510 and into a third inlet of a catalytic cracker 530, which cracks the heavy product stream 512 into a cracked product stream 532. The catalytic cracker 530 can also output a flue gas 534. The system 500 supplies the cracked product stream 532 from a seventh outlet of the catalytic cracker 530 and into a fourth inlet of the fractionator 510, in some embodiments. In some embodiments, the system 500 splits the heavy cycle oil stream 516 into two portions, a first portion of which is combined with the heavy product stream 512 to be recycled to the catalytic cracker 530. A second portion of the heavy cycle oil stream 516 is supplied to a fifth inlet of a mild hydrocracker 560, in some embodiments. Additionally, the light cycle oil stream 518 can be mixed or combined with the second portion of the heavy cycle oil stream 516 and provided to the fifth inlet of the mild hydrocracker 560. In certain embodiments, the heavy cycle oil stream 516 includes a boiling point ranging from 245-350 °C and the light cycle oil stream 518 includes boiling point ranging from 185-245 °C.

[0061] The mild hydrocracker 560 facilitates conversion of aromatic compounds that were previously produced in the catalytic cracker 530, in some embodiments. For example, the mild hydrocracker 560 can hydrocrack the second portion of the heavy cycle oil stream 516 and the light cycle oil stream 518 to produce a hydrocracked product stream 562. In certain embodiments, the mild hydrocracker 560 operates with reaction pressures between 50-150 bar and reaction temperatures between 300-500 °C. The mild hydrocracker 560 includes a fixed bed reactor provided with catalyst and a supply of hydrogen 564, in some embodiments, and can be used in either a riser configuration or a downer configuration. In certain embodiments, the mild hydrocracker 560 includes catalysts such as N1-WO3 / AI2O3, Ni-WCh / Zeolite and noble metal supported catalysts, such as Pt or Pd supported on zeolites (USY). In certain embodiments, the main products produced by the mild hydrocracker 560 include jet fuel, diesel, LPG, and / or naphtha.

[0062] In certain embodiments, the hydrocracked product stream 562 of the mild hydrocracker 560 is output via an eighth outlet of the mild hydrocracker 560 and supplied to sixth inlet of the fractionator 510, thereby recycling target compounds therein to extinction. In certain embodiments, the hydrocracked product stream 562 is supplied to any suitable additional or alternative location within the system 500. For example, the hydrocracked product stream 562 can be supplied to the catalytic cracker 530 along with the heavy product stream 512, in certainembodiments. In some embodiments, the hydrocracked product stream 562 can be supplied to the second inlet or fourth inlet of the fractionator 510, instead of a separate inlet. In any case, the system 500 including the mild hydrocracker 560 thus provides a second recycling loop for further upgrading of compounds into valuable chemical products.

[0063] In some embodiments, all or a portion of the naphtha product stream 520 is utilized for production of chemicals instead of gasoline. The naphtha product stream 520 is output from the fifth outlet of the fractionator 510, with a first portion of the naphtha product stream 520 supplied to a seventh inlet of a mixed feed 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 a naphtha blendstock 521, in certain embodiments. In some embodiments, the top product stream from the fractionator 510 includes fuel gas and / or LPG. A fuel gas stream 522 is separated from the top product stream and provided as a suitable fuel product, in some embodiments. Additionally, an LPG stream 524 can be separated from the top product stream, where a first portion of the LPG stream 524 is directed into an eighth inlet of the mixed feed steam cracker 570.

[0064] As previously described, the mixed feed 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 cracked product stream 572, which can be output via a ninth outlet of the mixed feed steam cracker 570. In some embodiments, the second cracked product stream 572 is mixed or combined with the second portion of the LPG stream 524 and supplied into a ninth inlet of an olefins separation unit 580. The olefins separation unit 580 can include a tenth outlet that outputs an olefins stream 582 as a suitable chemical product. Accordingly, the system 500 utilizing the mixed feed steam cracker 570 and the mild hydrocracker 560 can increase production of chemicals by around 50-70 wt.%, in certain embodiments.

[0065] Examples describe or illustrate selected aspects of the various embodiments of producing chemicals and fuels from gas condensates using improved FCC-based processes. Many modifications and other implementations of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated figures. Therefore, it is to be understood that the disclosure is not to be limited to the specific implementations disclosed herein and that modifications and other implementations are intended to be included within the scope of the appended claims. Althoughspecific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.EXAMPLES

[0066] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, articles, devices and / or methods claimed herein are made and evaluated and, therefore, are intended to be purely exemplary and are not intended to limit the disclosure. Efforts have been made to ensure accuracy with respect to numbers (such as amounts, temperature, and so forth), but some deviations should be accounted for.

[0067] There are numerous variations and combinations of reaction conditions, for example, component concentrations, desired solvents, solvent mixtures, temperatures, pressures and other reaction ranges and conditions that can be used to optimize the product purity and yield obtained from the described process. Only reasonable and routine experimentation will be required to optimize such process conditions. Example 1. Typical properties of hydrocarbon condensate feedstocks

[0068] The methods and systems disclosed herein implement suitable hydrocarbon condensate streams as a feedstock for improved yield of desired products. For example, Table 1 displays certain properties of three separate samples of hydrocarbon condensate.

[0069] Table 1 : The physical properties of example condensate feedstockExample 2. Composition of steam cracker product stream

[0070] In certain embodiments, the methods and systems disclosed herein utilize a steam cracker or mixed feed steam cracker to improve yield of desired chemicals. For example, Table 2 displays an example of product flows / yields from the steam cracker, which processes a condensate feed cut having a boiling point less than 185 °C.

[0071] Table 2: Steam cracker product effluent composition with less than 185 °C cut feedstock with recycling alkanes productsExample 3. Composition of catalytic cracker product stream

[0072] As discussed above, the methods and systems disclosed herein can utilize a catalytic cracker to upgrade compounds within hydrocarbon condensate for improved yield of desired chemicals and / or fuels. In certain embodiments, experiments can be performed to analyze conversion and product yield distribution for a catalytic cracker that includes a downer configuration and that is supplied with a product stream having a boiling point of 350 °C or above. In some embodiments, the reaction temperature can range between 600 to 675 °C, the steam / oil ratio can range between 0.1 to 0.5, and the catalyst to feed weight ratio can range from 5-30. In this example, the provided feedstock is fresh feedstock instead of recycled feedstock. Table 3 displays an example of product composition from a catalytic cracker having a reaction temperature 675 °C, a steam / oil ratio of 0.25, and a catalyst to feed weight ratio of 25.

[0073] Table 3: Catalytic cracker product effluent composition with typical 350 °C plus cut range feedstock

[0074] Other objects, features and advantages of the disclosure will become apparent from the foregoing figures, detailed description, and examples. It should be understood, however, that the figures, detailed description, and examples, while indicating specific embodiments of the disclosure, are given by way of illustration only and are not meant to be limiting. Additionally, it is contemplated that changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from the detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the specific embodiments described herein.

Claims

Claims1. A method comprising: providing a hydrocarbon condensate stream to a desalter to produce a desalted hydrocarbon condensate stream; providing the desalted hydrocarbon condensate stream to a fractionator to produce a first product stream and one or more second product streams, the first product stream having a boiling point that is greater than about 350 °C and the one or more second product streams each having a boiling point that is less than or equal to about 350 °C; providing the first product stream to a catalytic cracker to produce a cracked product stream; and recycling the cracked product stream to the fractionator.

2. The method of claim 1, further comprising providing at least one of the one or more second product streams to an olefins separation unit to produce an olefins-rich stream.

3. The method of claim 1, further comprising: providing at least one of the one or more second product streams to a steam cracker to produce a second cracked product stream; and providing the second cracked product stream to an olefins separation unit to produce an olefins-rich stream.

4. The method of any of claims 2 or 3, wherein the olefins-rich stream comprises more than 50 wt.% of ethene, propene, and butenes.

5. The method of claim 1, further comprising producing a gasoline stream from the one or more second product streams.

6. The method of claim 5, further comprising: providing one of the one or more second product streams to a catalytic reformer to produce a reformed product stream; and supplying the reformed product stream to a gasoline blending unit to produce the gasoline stream.

7. The method of claim 1, further comprising: providing one of the one or more second product streams to a hydrocracker to produce a hydrocracked product stream; and recycling the hydrocracked product stream to the fractionator.

8. The method of any of claims 1-7, wherein the hydrocarbon condensate stream comprises natural gas condensate having an American Petroleum Institute (API) gravity of about 45 to about 55.

9. A system comprising: a desalter configured to receive a hydrocarbon condensate stream and produce a desalted hydrocarbon condensate stream; a fractionator configured to receive the desalted hydrocarbon condensate stream from the desalter and produce a first product stream and one or more second product streams, the first product stream having a boiling point that is greater than about 350 °C and the one or more second product streams each having a boiling point that is less than or equal to about 350 °C; and a catalytic cracker configured to receive the first product stream, produce a cracked product stream, and recycle the cracked product stream to the fractionator.

10. The system of claim 9, further comprising an olefins separation unit configured to receive at least one of the one or more second product streams and produce an olefins-rich stream.

11. The system of claim 9, further comprising a steam cracker configured to receive at least one of the one or more second product streams and produce a second cracked product stream; andan olefins separation unit configured to receive the second cracked product stream and produce an olefins-rich stream.

12. The system of any of claims 10 or 11, wherein the olefins-rich stream comprises more than 50 wt.% of ethene, propene, and butenes.

13. The system of 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 a gasoline blending unit configured to receive at least the reformed product stream and produce a gasoline stream.

14. The system of claim 9, further comprising a hydrocracker configured to receive one of the one or more second product streams, produce a hydrocracked product stream, and recycle the hydrocracked product stream to the fractionator.

15. The system of any of claims 9-14, wherein the hydrocarbon condensate stream has an American Petroleum Institute (API) gravity of about 45 to about 55.

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