Conversion of gas condensate to value added petrochemicals in an integrated reactor process

Patent metadata

Field	Value
Publication number	US-12528997-B2
Application number	US-202418421129-A
Country	US
Kind code	B2
Filing date	Jan 24, 2024
Priority date	Jan 24, 2024
Publication date	Jan 20, 2026
Grant date	Jan 20, 2026

Abstract

Integrated processes for upgrading a hydrocarbon condensate stream to enhanced value streams including splitting a desalted feed stream into a light cut, a middle cut, and a heavy cut. The light cut is provided to a steam cracker unit to generate a steam cracked gas stream, a C4+ hydrocarbon stream, and a C9+ hydrocarbon stream, the middle cut is provided to a first catalytic cracker unit to generate a first cracked product stream, and the heavy cut is provided to a second catalytic cracker unit to generate a second cracked product stream. The steam cracked gas stream is provided to an olefins separation unit to generate at least one light olefin stream. Other effluents from the olefins separation unit and the steam cracker unit are provided to a hydrogenation unit, an aromatic extraction unit, or recycled within the system.

First claim

What is claimed is:

1 . An integrated process for upgrading a hydrocarbon condensate stream to enhanced value streams, the process comprising:
providing a feed stream comprising the hydrocarbon condensate stream to a desalter unit to remove salt from the feed stream to generate a desalted feed stream; providing the desalted feed stream to a first separation unit to split the desalted feed stream into a light cut, a middle cut, and a heavy cut, where the light cut and the middle cut are split at a first cut temperature in the range of 90° C. to 200° C. and the middle cut and the heavy cut are split at a second cut temperature in the range of 300° C. to 360° C.; providing the light cut to a steam cracker unit to generate a steam cracked gas stream, a C4+ hydrocarbon stream, and a C9+ hydrocarbon stream, wherein the C4+ hydrocarbon stream is rich in pyrolysis gasoline; providing the middle cut to a first catalytic cracker unit with a first catalyst disposed therein to generate a first cracked product stream; providing the heavy cut to a second catalytic cracker unit with a second catalyst disposed therein to generate a second cracked product stream; providing the first cracked product stream and the second cracked product stream to a fractionation tower to generate a cracked gas fraction, a catalytic cracked naphtha fraction, a light cycle oil fraction, and a heavy cycle oil fraction; providing the steam cracked gas stream and the cracked gas fraction to an olefins separation unit to generate at least one light olefin stream comprising C3 and lighter olefins, a first light hydrocarbons stream comprising C2-C4 alkanes, a second light hydrocarbons stream comprising C2-C4 dienes and 2-butenes, and a fuel gas stream comprising hydrogen and methane; providing the first light hydrocarbons stream to the stream cracker unit and the second light hydrocarbons stream to a hydrogenation unit; providing the C4+ hydrocarbon stream to an aromatic extraction unit to generate an aromatics product stream and a residual stream; providing the residual stream to one or both of the first catalytic cracker unit and the hydrogenation unit to hydrogenate C5 to C9 hydrocarbons and generate a hydrogenated hydrocarbon stream; and providing the hydrogenated hydrocarbon stream to one or both of the steam cracker unit and the first catalytic cracker unit.

2 . The process of claim 1 , wherein the hydrocarbon condensate stream comprises a natural gas condensate.

3 . The process of claim 2 , wherein the natural gas condensate comprises an API range from 45 to 55.

4 . The process of claim 1 , wherein the first cut temperature is in the range of 90° C. to 100° C. and the second cut temperature is in the range of 300° C. to 360° C.

5 . The process of claim 4 , wherein the second cut temperature is 350° C.

6 . The process of claim 1 , wherein the first cut temperature is in the range of 150° C. to 200° C. and the second cut temperature is in the range of 300° C. to 360° C.

7 . The process of claim 6 , wherein the second cut temperature is 350° C.

8 . The process of claim 6 , wherein the light cut from the first separation unit is provided to a second separation unit to generate a paraffinic rich naphtha stream and an aromatics rich stream, where the paraffinic rich naphtha stream and the aromatics rich stream are cut at a temperature in the range of 90° C. to 110° C.

9 . The process of claim 8 , wherein the paraffinic rich naphtha stream is provided to the steam cracker unit in lieu of the light cut.

10 . The process of claim 8 , wherein the aromatics rich stream is provided to the aromatics extraction unit.

11 . The process of claim 1 , wherein the desalted feed stream is hydrotreated to remove nitrogen and sulfur before feeding to the first separation unit.

12 . The process of claim 1 , wherein the process further comprises providing the light cycle oil fraction and the C9+ hydrocarbon stream to a diesel preparation unit to generate a diesel fuel stream or diesel blend stream.

13 . The process of claim 1 , wherein the heavy cycle oil fraction is recycled as a feed stream to the second catalytic cracker.

14 . The process of claim 1 , wherein the aromatics extraction unit additionally generates a residual stream, the residual stream recycled as an input to the first catalytic cracker unit.

15 . The process of claim 1 , wherein the aromatics extraction unit additionally generates a residual stream, the residual stream recycled as an input to the hydrogenation unit.

16 . The process of claim 1 , wherein the cracked gas fraction comprises hydrogen and hydrocarbons boiling at less than 30° C., the catalytic cracked naphtha fraction comprises hydrocarbons boiling in the range of 30° C. to 185° C., the light cycle oil fraction comprises hydrocarbons boiling in the range of 185° C. to 350° C., and the heavy cycle oil fraction comprises hydrocarbons boiling at greater than 350° C.

17 . The process of claim 1 , wherein the first catalytic cracking unit is operated at a temperature between 60° and 700° C., a catalyst to feed weight ratio of 2 to 40, and a residence time of 0.1 to 4 seconds.

18 . The process of claim 1 , wherein the first catalyst comprises a mixture of 10 to 75 weight percent of a rare earth metal modified USY and 10 to 90 weight percent of a ZSM-5 zeolite.

19 . The process of claim 1 , wherein the second catalytic cracking unit is operated at a temperature between 50° and 650° C., a catalyst to feed weight ratio of 2 to 40 and a residence time of 0.1 to 4 seconds.

20 . The process of claim 1 , wherein the second catalyst comprises a mixture of 20 to 80 weight percent of a rare earth metal modified USY and 20 to 80 weight percent of a ZSM-5 zeolite.

Assignees

• Sabic Global Technologies Bv
• Saudi Arabian Oil Co

Inventors

• Vuppula Rajitha
• Guggilla Vidya Sagar
• Nijhuis Tjeerd Alexander
• Jagani Venkata Sunil
• Juttu Gopal

Classifications

• C10G2400/20

  C2-C4 olefins · CPC title

• C10G2300/4006

  Temperature · CPC title

• C10G2300/202

  Heteroatoms content, i.e. S, N, O, P · CPC title

• C10G2300/1096

  Aromatics or polyaromatics · CPC title

• B01J29/80

  Mixtures of different zeolites · CPC title